Method and apparatus for efficient package delivery and storage

ABSTRACT

A method and system for the efficient bulk package delivery for recipients. Items ordered by different customers from different retailers, suppliers or manufacturers can be organized by common item identifiers and shipped in bulk from retailers or manufacturers, to an origination regional distribution center. The items can be sorted at the origination regional distribution center in bulk based on the location of destination regional distribution centers that can serve destination centralized pickup locations chosen by the customers placing the orders for those items. Ordered items can be sorted by recipient and the destination centralized pickup location specified in the customer&#39;s order and packed into recipient-specific packages at the destination regional distribution center. The packages can be transported in bulk to the destination centralized pickup locations where they can be randomly loaded into any available locker bins in an automated system of stationary and moveable, configurable storage locker bins. During loading, an association can be made between an identifier of the locker bin and an identifier of the bulk delivered package for subsequent self service identification and retrieval. An electronic notification of the delivery can be automatically dispatched to the recipient by the automated system of storage locker bins to alert the recipient of the delivery.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention pertains to the general field of storage and delivery ofordered items. More particularly, the invention pertains to an efficientmethod for handling the bulk delivery of articles from a depot into anautomated article storage and retrieval system at a centralized articlepickup location.

2. Description of the Related Art

The Internet has provided tremendous opportunities for the sales ofproducts in the retail business. Consumers can easily go online using acomputer, personal digital assistant (PDA), or even a cellular phone,and readily access a plethora of web sites that offer a wide range ofproducts. Notwithstanding the fact that online businesses can offerlower prices to consumers because of lower overhead costs, consumers andretailers can be disadvantaged by the cost associated with shipping andhandling. For example, the effective cost of ordering a bottle ofshampoo and a toothbrush which might cost $4.00 could be $9.00 due tothe cost of shipping and handling. As a result of the added cost ofshipping and handling, it is currently impractical to order low costitems unless the cost of shipping and handling can be significantlyreduced. Even for higher priced items, the shipping and handling costsassociated with each order can be tolerable for an occasional purchase,but are prohibitive when added up across the frequency of purchase aconsumer normally makes.

In order to reduce the cost of shipping and handling, more efficientmethods and systems of delivery are required. In current deliverymethods and systems, ordered items may be picked at a retailer'sfulfillment site in batches, but each order is handled in a singularmanner. A recipient of a product may place an order to a retailer. Theretailer accepts the order, packages the ordered item and then ships thepackage along with other packages via a package delivery service. Oncethe package delivery service picks up the package from the retailer, thepackage is usually taken to an initial distribution center where it issorted according to the destination address of the recipient. It willthen be shipped by air, land or sea to one or more distribution centerswhere it is resorted every time. Once the package reaches thedistribution center that services the recipient locale, the package willbe transported on a delivery truck, along with other packages to bedelivered in that local area, to the customer-specified address of eachpackage on the delivery truck, until the delivery truck reaches thecustomer-specified address of the recipient's package for finaldelivery.

Inherent in these delivery and handling processes are numerousinefficiencies that in the end, result in increased cost. Firstly, thepackages of ordered items are packed inefficiently for the entiredistance that they are transported. This is due to the nature of tryingto pack items of different shapes and sizes into a box or container thatis large enough to hold all the items, with added packing materials toprevent the differently shaped items from damaging each other duringtransport. Secondly, packages are moved from cargo-carrying vehicles andpackages sorting facilities a numerous amount of times as packages aredistributed. The packages are moved from a delivery vehicle to afacility and vice-versa. At each point that a package changes hands whenbeing routed through a package shipper's distribution network, it isresorted and grouped with other packages to fit onto the nextcargo-carrying vehicle. This translates to an increased shipping andhandling cost. Thirdly, each package delivered to its final distributioncenter has to be carried on an individual basis to the recipient'sdelivery address. The packages are delivered to recipient addresses onsmaller cargo-carrying vehicles and can only be delivered duringreasonably acceptable business hours. If the recipient is not availableat the time of the attempted delivery, a package may either be leftoutside of a recipient's home where it is susceptible to theft,mischief, or weather damage, or it may remain undelivered until afurther delivery attempt is made. The shipping cost is furthercompounded in instances where several attempts have to be made tofinalize the delivery.

Analysts have predicted that the buying habits of mainstream consumerswill change, in the near future, to one that is heavily dependent on theInternet. In addition to the inefficiencies described above, if and whenthis growth occurs, the current delivery methods and infrastructure willbe vastly inadequate to accommodate this growth.

Given these inefficiencies, there exists a need to achieve moreefficient methods and systems for delivering packages.

SUMMARY OF THE INVENTION

The invention discloses a method and system for efficient bulk packagedelivery for recipients. The method for efficient bulk package deliveryfor recipients can include the steps of delivering the packages in bulkfor a plurality of recipients in a single delivery stop to a destinationcentralized pickup location and loading the bulk delivered packagesrandomly into an automated system of storage locker bins. The step ofdelivering the packages in bulk for a plurality of recipients canfurther include, delivering items destined for recipients of thepackages. The step of delivering the packages in bulk can include thestep of sorting at an central location, for example an originationregional distribution center (RDC), items received from a plurality ofretailers delivered to the origination RDC location, the items beingorganized by a common item identifier and destined for a plurality ofrecipients.

The step of sorting the received items at the origination RDC locationcan be further comprised of the steps of identifying the received itemsbased on their destination centralized pickup location, or theirdestination local distribution hub. Additionally, the received items canbe identified to a destination RDC location. The identified items whichare organized by a common item identifier can be sorted and groupedbased on the identified destination RDC.

In one aspect of the invention, the step of delivering packages in bulkcan include transporting the sorted and grouped items to the identifieddestination RDC, sorting the transported items by either the destinationcentralized pickup location or a destination local distribution hub, andcreating the bulk delivered package by organizing the sorted items for aspecific recipient. The sorted items can be sorted by either adestination centralized pickup location or a destination localdistribution hub. The created bulk delivered package having itemsorganized for a specific recipient can then be transported in bulk tothe destination centralized pickup location selected when the customerplaced the order or to the destination local distribution hub servingthe area in which the customer specified address is located, if acustomer specified address was entered.

In a further aspect of the invention, the step of creating the bulkdelivered package at the destination RDC location can further includelocating items destined to a specific recipient from items organized bythe common item identifier. The method can further include consolidatingitems originating from more than one retailer, destined to the specificrecipient. The method can further include receiving the located itemsassociated with a single order from more than one fulfillment location,the fulfillment location being at least one of a retailer, amanufacturer, a merchant and a supplier.

The step of randomly loading the bulk delivered package into anautomated system of storage locker bins can further include capturingelectronically, an identifier for the bulk delivered package, andassociating the electronically captured identifier of the bulk deliveredpackage with an electronically captured identifier of one of the storagelocker bins within the automated system of storage locker bins. The bulkdelivered package created for a specific recipient can be retrieved froma storage locker bin. Suitable electronics and circuitry can be used tofacilitate authenticating an identity of the recipient prior torevealing the identity of the storage locker bin and/or providing accessto that storage locker bin.

In a further aspect of the invention, the method for efficient bulkpackage delivery can further include creating a returns package havingone or more items from either the bulk delivered package retrieved by arecipient and or packages delivered to a customer specified address,wherein the returns package can be destined for a retailer associatedwith the items of the returns package. Sorted and grouped createdreturns packages can be delivered in bulk to returns facility of theassociated retailer. The invention can further include submitting thereturns package for pickup at a destination centralized pickup location.

A further aspect of the invention can include creating a returns packagethat can consist of at least one item from either a bulk deliveredpackage retrieved by a recipient and a package delivered to a customerspecified address, the returns package destined for the retailerassociated with the items of the returns package. A returns facilityidentifier and a returns local market identifier can be identified basedupon an identifier of the retailer. An origination RDC identifierassociated with the identified returns local market identifier can alsobe identified. The returns package can be submitted for pickup at adestination centralized pickup location. The submitted returns packagecan be transported from the destination centralized pickup location ofthe returns package submission, to a destination RDC associated with thedestination centralized pickup location of returns package submission.At the associated destination RDC, the transported returns package canbe sorted and grouped by the RDC identifier associated with the returnslocal market identifier identified for the returns package for bulkdelivery to an origination RDC associated with the identified RDCidentifier. The sorted and grouped returns package can be transportedfrom the associated destination RDC to the associated origination RDC.At the associated origination RDC, the transported returns package canbe sorted by the identified returns local market identifier of thereturns package. At the associated origination RDC, the sorted returnspackage can be sorted and grouped according to the identified returnsfacility identifier of the sorted returns package for bulk delivery to areturns facility associated with the returns facility identifier. Thesorted and grouped returns package can be delivered to the associatedreturns facility.

In a further aspect of the invention, the step of randomly loading thebulk delivered package into the automated system of storage locker binscan include automatically triggering the dispatch of an electronicnotification to the recipient of the bulk delivered package, theelectronic notification having at least an identifier of the destinationcentralized pickup location. Suitable electronic circuitry and softwarecan be used to facilitate the triggering and dispatch functions.

The step of automatically triggering the dispatch of the electronicnotification can further include recording information necessary forbilling at least one of the retailer shipping the ordered items of thebulk delivered package, a customer who ordered the item of the bulkdelivered package, and the recipient of the bulk delivered package. Theinformation can include at least one of an order identifier, an orderingcustomer identifier, a recipient identifier or a customer identifier, apackage identifier, a delivery date, a delivery time, a deliverynotification date, a delivery notification time, a retrieval date and aretrieval time, or any combination thereof. The electronic notificationto the recipient can be a facsimile, an email, a telephone call, and apage or any combination thereof.

In a further aspect of the invention, the delivery method can furtherinclude retrieving the bulk delivered package by the recipient throughself-service. Prior to retrieval, the package must be delivered andloaded into the storage bin. The step of loading the bulk deliveredpackage randomly into the automated system of configurable storagelocker bins can include the step of loading the bulk delivered packageinto any unoccupied storage locker bin within the automated system ofconfigurable storage locker bins, having dimensions that are largeenough to accept the bulk delivered package. The temperature within thebins of the automated system of storage locker bins can also becontrolled by locating the bins in a temperature-controlled environment.

The step of delivering the package in bulk to a destination centralizedpickup location can further include accommodating the delivery of thepackage in bulk to the destination centralized pickup location from aplurality of different shippers. The loading of the bulk deliveredpackage randomly into the automated system of storage locker bins canfurther include accommodating the loading of the delivered package intothe automated system of storage locker bins from a plurality ofdifferent shippers.

Alternately, the step of delivering the package in bulk to thedestination centralized pickup location can further include, creatingthe bulk delivered package at a retailer fulfillment site, the bulkdelivered package containing at least one ordered item organized for aspecific recipient. In a further aspect of the invention, either aspecified destination centralized pickup location or a destination localdistribution hub can be determined for the bulk delivery of the package.Similarly, a destination RDC for the bulk delivered package can also bedetermined. The bulk delivered package can then be transported from theretailer fulfillment site to an origination RDC, where the transportedbulk delivered package can be sorted and grouped based on its determineddestination RDC. The bulk delivered package can be transported from theorigination RDC to the determined destination RDC. At the destinationRDC, the transported bulk delivered package can then be sorted andgrouped for bulk delivery by its previously determined destinationcentralized pickup location or destination local distribution hub. Thebulk delivered package can be delivered to the previously determinedpickup location and or the local distribution hub in bulk with the otherbulk delivered packages with which it has been grouped.

In another aspect of the invention, the step of delivering the bulkdelivered package to the destination centralized pickup location canfurther include creating the bulk delivered package at a retailerfulfillment site, with the bulk delivered package containing at leastone item organized for a specific recipient. The specified destinationcentralized pickup location or the destination local distribution hubcan be determined for the bulk delivery of the created bulk deliveredpackage. Based on the determined specified destination, the bulkdelivered packages can be sorted and grouped at the retailer fulfillmentsite for bulk delivery. The packages can be delivered in bulk from theretailer fulfillment site to the determined specified destination.

The method for efficient bulk package delivery can further includecreating a bulk delivered CDC outbound package consisting of at leastone item destined for a recipient at a specified destination centralizedpickup location or a specified address, submitting the bulk deliveredCDC outbound package for pickup at a destination centralized pickuplocation, and delivering the CDC outbound package in bulk to either thespecified destination centralized pickup location or a destination localdistribution hub.

In yet another aspect of the invention, the method for efficient packagedelivery can also include a method for efficient package creation. Themethod for efficient package creation can include determining either aspecified destination centralized pickup location or a destination localdistribution hub for delivery of at least one item destined for arecipient. Items can be located for a specific recipient and thespecified destination centralized pickup location or the localdistribution hub from said items within a destination RDC, with theitems being organized by a common item identifier. The located items canbe consolidated into a package to be delivered to either the destinationcentralized pickup location or the destination local distribution hubfor a recipient. The located items can originate from one or moreretailers.

The method for efficient package creation can further include deliveringin bulk items that can be organized by a common item identifier from aretailer to an origination RDC to fill an order destined for therecipient. A destination RDC can be determined for the items based on apredefined relationship between a series of local markets served by adestination RDC and a local market of the determined one of a specifiedpickup location and a local distribution hub. The items can betransported from the origination RDC to the determined destination RDC.

In yet another aspect of the invention, a method for efficient packagecreation can include delivering items organized by a common itemidentifier in bulk from a retailer to an origination RDC to fill anorder destined for a recipient. A destination RDC can be determined forthe delivered items based upon the destination delivery location of theorder destined for the recipient, and the items can be transported fromthe origination RDC to the destination RDC. At the destination RDC,items destined for a specific recipient can be located from the itemsorganized by a common item identifier, and the located items can beconsolidated into a package destined for that recipient. The locateditems, which can be consolidated into a package for a recipient, canoriginate from more than one retailer if items for more than one orderdestined for the recipient have been received into the destination RDC.

In a further embodiment of the invention, a system for efficient bulkpackage delivery for recipients is disclosed. The system can include adelivery means for delivering of the packages in bulk for recipients byusing a single delivery stop to a destination that can be a centralizedpickup location and a means for randomly loading bulk delivered packagesinto an automated system of storage locker bins. The delivery means fordelivering of the packages in bulk can include a means for sorting at aRDC location, items received from suppliers, which can include but arenot limited to, retailers, manufacturers, wholesalers, and distributors,delivered to the origination RDC location. The items can be destined forrecipients and can be organized by a common item identifier or SKU.

The means for sorting the received items at the origination RDC locationcan include identification means for identifying the received itemsaccording to a destination centralized pickup location or a destinationlocal distribution hub, and a destination RDC for the received items.The means for sorting the received items can also include means forsorting and grouping the identified received items by the identifieddestination RDC, the grouped items being organized by a common itemidentifier.

The means for delivering the packages in bulk can include atransportation means for shipping sorted and grouped items to thedestination RDC, means for sorting at the destination RDC, the receiveditems by either a destination centralized pickup location or adestination local distribution hub. The means for delivering thepackages in bulk can also include means for creating at the destinationRDC, the bulk delivered package by organizing the items sorted by thedestination centralized pickup location or the destination localdistribution hub for a specific recipient and a transportation means forshipping the created bulk delivered package to either the destinationcentralized pickup location or the destination local distribution hub.

In a further aspect of the invention, the means for randomly loading thebulk delivered package into the automated system of storage locker binscan comprise means for capturing electronically, an identifier or SKUfor the bulk delivered package and means for associating theelectronically captured identifier of the bulk delivered package with anelectronically captured identifier of one of the storage locker binswithin the automated system of storage locker bins. The means forrandomly loading the bulk delivered package into the automated system ofstorage locker bins can also include suitable electronic circuitry andsoftware for automatically triggering the dispatch of an electronicnotification to a recipient of the bulk delivered package. Theelectronic notification can have at least an identifier of thedestination centralized pickup location. The circuitry and associatedsoftware can record information necessary for billing customers,retailers, suppliers and or recipients.

BRIEF DESCRIPTION OF THE DRAWINGS

There are presently shown in the drawings embodiments of which arepresently preferred, it being understood, however, that the invention isnot so limited to the precise arrangements and instrumentalities shown,wherein:

FIG. 1 is an illustrative flow diagram of the processing that occurs atthe various distribution centers from the moment of capturing a customerorder to the point of a recipient retrieving a delivered packagecontaining the ordered items from a Customer Distribution Center (CDC),wherein the ordered items are distributed through two separatedistribution facilities before being delivered to the CDC or a localdelivery distribution hub (LDDH)—an origination regional distributioncenter (RDC) and a destination RDC.

FIG. 1A is an alternate illustrative flow of the embodiment of theprocessing described in FIG. 1, wherein the ordered items aredistributed through only one distribution facility before beingdelivered to the CDC or LDDH—a RDC which serves as both the originationRDC and the destination RDC for those ordered items.

FIG. 2 is an illustrative embodiment of the various exemplary entitiesof the delivery process and their relative location to each other.

FIG. 3 is an illustrative embodiment of an exemplary layout of aRegional Distribution Center (RDC).

FIG. 4 is an illustrative embodiment of an exemplary package creationside of a Customer Distribution Center (CDC) Packing Station.

FIG. 5 is an illustrative embodiment of an exemplary Package Sealingside of a Customer Distribution Center (CDC) Packing Station.

FIG. 6 is an illustrative embodiment of an exemplary layout of aCustomer Distribution Center (CDC).

FIG. 7 is an illustrative embodiment of an exemplary layout of a PackageCreation Screen.

FIG. 8 is a view of an exemplary tractor-trailer parked at an exemplaryshipping or receiving dock area.

FIG. 8A is a detailed layout of an exemplary local market shipping dockarea within a RDC.

FIG. 9A shows various illustrative embodiments of exemplary tables anddata views for the distribution system and method.

FIG. 9B is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 9C is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 9D is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 9E is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 9F is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 9G is a continuation of the exemplary data tables and data views ofFIG. 9A.

FIG. 10A is an illustrative embodiment of exemplary data tables and dataviews used in conjunction with the automated system of storage lockerbins.

FIG. 10B is a continuation of the exemplary data tables and data viewsof FIG. 10A.

FIG. 10C is a continuation of the exemplary data tables and data viewsof FIG. A.

FIG. 10D is a continuation of the exemplary data tables and data viewsof FIG. 10A.

FIG. 11A is a list of exemplary application and programs of thedistribution method and system disclosed in FIG. 1.

FIG. 11B is a continuation of the exemplary list of FIG. 11A.

FIG. 12 is an illustrative embodiment of an exemplary SmartBin Unit(SBU) containing storage locker bins within an automated system ofstorage locker bins.

FIG. 13 is an illustrative flow diagram of the processing that occurs atthe various distribution centers in sending an item return package froma CDC to a retailer's returns processing facility and/or in sending aCDC outbound package from one CDC to another CDC for a recipient.

DETAILED DESCRIPTION OF THE INVENTION

There is shown in FIG. 1, an embodiment of the instant inventiondepicting illustrative steps that can be used to efficiently deliverpackages in bulk, wherein ordered items of that bulk delivered packageare processed in two separate distribution facilities before beingdelivered to a customer distribution center (CDC) or a local deliverydistribution hub (LDDH)—an Origination regional distribution center(RDC) and a Destination RDC. Customers can place orders with retailersor manufactures. In step 1100, these orders can be captured by theretailer. Following capture of the orders, in step 1102, retailers canfill the orders by picking cases of the ordered items to meet the totalordered quantity of each item across all unfilled orders. As cases ofordered items get picked from the inventory in their fulfillmentoperations, the retailer's workers can label each case with a packagelabel. The cases of ordered items can be organized into one or moreretailer shipments on shipping docks of a retailer's fulfillment site.In step 1106, the shipments of items prepared by the retailer can beloaded onto a carrier, such as, a tractor-trailer via a system of dockand trailer conveyors. Steps 1100, 1102 and 1106 can be carried out at aretailer fulfillment center 1194.

In step 1108, the cases of items can then be then shipped to the nearestregional distribution center which serves as an origination RegionalDistribution Center (RDC) 1170 for all items received from retailers. Instep 1110, the cases of shipped items can be received at the originationRDC 1170 and sorted by a RDC identifier (RDC Id) in step 1112. After theitems are sorted, they can be shipped in cases to the destination RDC'sidentified on their case labels, for example RDC 1180-1, as shown instep 1114. The item cases can then be received into a destination RDC asshown in step 1116, where a local market sort can be performed as shownin step 1118. Following the local market sort 1118, a CDC sort, step1120, can be performed at the destination RDC 1180-1. This sorting leadsto the creation of packages, step 1122, consisting of items for a commonrecipient that are destined to be delivered to an identified commoncustomer distribution center (CDC) 1190-1 (FIG. 2) or a common localdelivery distribution hub (LDDH) 1192-1. The resulting packages, whichare already organized by a CDC identifier (CDC Id), can then be groupedand loaded into special crates in order to create a delivery shipment ofpackages, step 1124, which can be shipped from the destination RDC1180-1. The delivery shipment of packages can be shipped in bulk to alocal delivery distribution hub (LDDH) 1192-1, step 1126, or to a CDC1190-1, step 1128. Packages can be shipped to a LDDH 1192-1, wheneverthe packages are to be delivered to a customer-specified location.Packages can be shipped in bulk to a CDC 1190-1 whenever the recipientcan be expected to pickup the package at a destination centralizedpickup location (or CDC) 1190-1. If the packages are received into thelocal delivery distribution hub 1192-1, step 1130, they can be sortedby, for example, recipient zip code, step 1132. The sorted packages canthen be loaded onto delivery trucks, step 1134, where they can bedelivered to the individual recipient addresses as shown in step 1136.The retailers can then be billed for the orders they shipped, step 1138,following the delivery step 1136. Also shown in FIG. 2, is a customerdistribution center (CDC) 1190-4 and a local delivery distribution hub(LDDH) (1192-4).

If the packages are destined to a destination centralized pickuplocation (or CDC) 1190-1 being served by the destination RDC 1180-1,then, following the shipment step 1128, the packages can be received inbulk at the CDC 1190-1, step 1142. Following the receipt of deliverystep 1142, the bulk delivered packages can be loaded into an automatedsystem of storage lockers such as SmartBin units (SBU's), step 1144. Theloading step 1144 can trigger automatic notifications of the delivery tothe recipients, step 1148. Following the notification step 1148, theretailers can then be billed as shown in step 1138, and the recipientscan then retrieve their packages from the automated system of storagelockers, step 1150. Returning to the receipt of delivery shipment step1142 at the CDC 1190-1, in addition to receiving packages shipped inbulk from the destination RDC 1180-1, step 1142, bin configurationadjustments can be performed, step 1140, prior to step 1142.

There is shown in FIG. 1A, a different illustrative example of theembodiment depicted in FIG. 1. The illustrative example shown in FIG. 1Adepicts the steps that can be used to efficiently deliver in bulkpackages of items, which are ordered from a retailer having afulfillment site 1194 in a local market served by one of a shipper'sRDC's 1170, for delivery to a CDC 1190 or customer specified addresslocated in a local market served by that same RDC 1170. In thisillustrative example, the cases of items can be received into anorigination RDC 1170 using the same steps as depicted in FIG. 1, steps1100 through 1110. Some of those cases of items—the ones containingitems to be processed into one or more packages to fill orders to bedelivered to CDC's 1190 or customer-specified addresses in a localmarket served by the origination RDC 1170—can be moved into the localmarket sort step 1118 from the RDC sort step 1112, within the RDC 1170,which serves as both an origination RDC and a destination RDC for thosecases of items. The local market sort step 1118 and all the steps thatfollow it in this illustrative example of the process, steps 1120 to1150, can be performed in the illustrative example of FIG. 1A consistentwith the way they are performed in the illustrative example of FIG. 1.

Referring now to FIG. 2, and by way of example, an illustrative deliveryprocess consistent with the principles of the invention is described.The example illustrated by FIG. 2, describes the delivery process fromthe view point of one shipper, as it depicts the interaction between thedifferent RDC's of one shipper and the interaction of those RDC's withretailer fulfillment sites, CDC's, and LDDH's. Each one of a shipper'sRDC's can serve as an origination RDC for cases of items received fromretailers, and as a destination RDC for some of those cases receivedfrom retailers (as depicted in FIG. 1A) and for cases of items receivedfrom other RDC's (as depicted in FIG. 1). For simplicity in referring toan origination RDC and a destination RDC within this illustrativeexample corresponding to FIG. 2, an origination RDC will be referred toas RDC 1170 and a destination RDC will be referred to as RDC 1180-1.Consistent with the numbering in FIG. 2, CDC's and LDDH's will bereferred to as CDC 1190-1 and LDDH 1192-1 respectively when describingCDC's or LDDH's related to a destination RDC. Retailer fulfillment sitesrelated to an origination RDC will be referred to as retailerfulfillment site 1194 in the illustrative example description of FIG. 2.The multiple overlapping shapes behind a retailer fulfillment site1194-1, CDC 1190-1, and LDDH 1192-1 represent that there can be aplurality of instances of that type of facility related to each RDCfacility depicted in FIG. 2. Accordingly, any reference to an entityrepresented by a numbered multiple overlapping shape can be a referenceto any one of the plurality of instances of that type of entity.

The processing steps of the following illustrative example refer to FIG.1 in addition to FIG. 2 and other figures as stated, except wherespecifically noted as referring to FIG. 1A. The delivery process canbegin with customers placing orders with retailers or manufacturers thatcan accept orders via the internet, television shopping programs,mail-order catalogs, or any other means of placing an order fordelivery. The term “retailer” will be used throughout this disclosure torefer to a retailer, manufacturer or other equivalent business thataccepts orders for processing. Furthermore, a retailer may operate morethan one order fulfillment site to process orders. If two or moredistinct order fulfillment sites can be operated by the same retailer,each one can be identified by a different ePD Retailer Id. Throughoutthis disclosure each entity identified by an ePD Retailer Id will bereferred to as a retailer, even if it is only representing one of aretailer's order fulfillment sites. The customer orders can be capturedby the retailer as shown in step 1100. In most situations, customersplacing the order can identify themselves as the recipient of thatorder, but a customer can also place an order for a different recipient.Throughout this disclosure, the entity placing an order will always bereferred to as a customer, and the entity receiving (picking up) anorder will always be referred to as a recipient, even though thecustomer and the recipient can be the same entity for many orders. Inone aspect of the invention, customers can be given the capability tochoose a delivery option. In addition to the existing delivery optionsthat can be currently offered by package shippers (standard delivery andvarious forms of express delivery), retailers can also offer the moreefficient ePackage Depot (ePD) delivery option. The ePD delivery optioncan typically be priced lower than other delivery options, since itrequires the recipient to pickup their order from a customerdistribution center (CDC) (or destination centralized pickup location)1190-1. ePD delivery service may be provided by one or more packageshippers or other organizations. A package shipper or other organizationproviding the ePD delivery service will be referred to throughout thisdisclosure as a “shipper”. A shipper providing the ePD delivery servicecan also provide the traditional package delivery service of deliveringa package to a customer specified address.

Customers who choose the ePD delivery option can enter their ePDcustomer identification number (Customer Id) and choose the CDCidentifier (CDC Id) of a CDC 1190-1 where they want to pick-up theirorder. Customers who have used the ePD option in the past can beoptionally shown (on a web page or be told over the phone) a defaultdestination centralized pickup location (CDC) 1190-1—one that thecustomer previously provided as a preference or the last CDC 1190-1 theyselected if they have not provided a preference. At this point acustomer can select the default CDC 1190-1, input a different CDC Id orsearch for a different suitable CDC 1190-1 by providing appropriatesearch criteria including, but not limited to a zip code, a city name ora street name. Upon entering the appropriate search criteria, a customercan receive a listing of the nearby CDC locations 1190-1, for example,through a web page or over the phone. As an illustrative example, thelisting can have the top five closest CDC locations 1190-1 to the searchcriteria. CDC's 1190-1 returned from a search can be listed in orderfrom closest to farthest. If city is entered, a complete listing of CDClocations 1190-1 within or near the metro area of the entered city canbe given including the full address of those CDC locations 1190-1.

Customers who are new to the ePD Delivery Process can be prompted toprovide information necessary to set themselves up as new customers inthe ePD Billing & Maintenance application via a linked internet web pageor over the phone by a person taking their order who can access the ePDcustomer setup screen on the internet web page. The ePD Billing &Maintenance application can be a database and a set of programs tocapture and maintain data related to customers, recipients, retailers,CDC's, RDC's, and shippers for use in the shipping operations of all ePDshippers. Exemplary information, which can be recorded to set up acustomer or a recipient can include, but is not limited to name, socialsecurity number, zip code, CDC preference, primary contact phonenumber/e-mail address, and a secondary contact phone number/e-mailaddress. The type of contact can be recorded for both primary andsecondary contacts. A calling window start time and end time can also berecorded for phone number contacts. Credit card or other paymentinformation does not have to be captured for the ePD customer set up,but can be maintained or recorded by the retailer as part of acustomer's order. In one embodiment, shipping costs for ePD delivery canbe billed by shippers to retailers based on customer orders. Retailersmay in-turn bill their customers for shipping by payment methods theyestablish with those customers.

In an alternate embodiment of the invention, shippers can bill retailersfor each package based on package size instead of a flat shipping feeper order, a fee based upon the number of items in an order, a fee basedupon the weight of an order, a fee based upon the value of an order, ora fee based upon other order-based factors. Alternately, shippers canbill the customers placing orders, instead of the retailers acceptingthose orders. The amount billed can be based upon factors including, butnot limited to a flat shipping fee per order, a fee based upon thenumber of items in an order, a fee based upon the weight of an order, afee based upon package size, a fee based upon the number of packages inan order, location-based storage rates, and seasonal-based storagerates.

In another aspect of the invention, the entity operating a CDC cancharge retailers, shippers, or customers a storage fee for each packageor order delivered based upon factors which can include, but are notlimited to, the number of SBU bins used to hold the packages of anorder, the size of each SBU bin used to hold each package, the amount oftime that a package is in a SBU bin after the package recipient wasnotified of delivery, a flat storage charge per order, a storage chargebased upon the value of an order, a flat storage charge per packagedepending upon package size, location-based storage rates, andseasonal-based storage rates.

With reference to FIG. 9E and FIG. 10B, customer, recipient, CDC,shipper, and employee information can be maintained centrally on themaster copies of a Customer table 1256, a CDC table 1252, a Zip Code-CDCtable 1254, a Shipper table 1260, and an Employee table 1308 of the ePDBilling & Maintenance Application. Although a recipient can be adifferent entity than a customer, recipient information can bemaintained on the Customer table 1256 and can be required by a retailerwhen an order is placed for that recipient. Read-only copies of theCustomer table 1256, CDC table 1252 and Zip Code-CDC table 1254 can bemaintained in the database of each retailer's instance of an ePDShipping Application by replicating data from the ePD Billing &Maintenance Application's master tables. A different instance of the ePDShipping Application can be run by each retailer and shipper tofacilitate the process of accepting customer orders for both ePDdelivery to a CDC 1190-1 and traditional delivery to acustomer-specified address and shipping ordered items from retailerfulfillment sites 1194 to shipper origination RDC's 1170. In referringto an “instance” of a program or an application throughout thisdisclosure, each instance contains the same basic software program orset of software programs, but the programs of each instance can be runagainst the same database instance or a different database instance andcan have different pre-defined program values in a referenced file.Different instances of a database can have the same table and fieldstructures, but different data values. In order to accept and processcustomer orders, the ePD Shipping Application can be integrated with thedifferent order processing systems used by different retailers. The ePDShipping Application can be integrated with each order processing systemin such a way as to minimize the amount of change to the retailer'ssystem while providing the necessary data and functionality to enablethe shipper to use the ePD Shipping Application to support the ePDDelivery Process.

An instance of the ePD Shipping Application can run on a retailerworkstation or server computer. Referring to FIG. 9A, Order informationcan be recorded in an Order Header table 1200 and an Order Detail table1202 of the ePD Shipping Application as both ePD delivery orders andtraditional delivery orders are taken by retailers. Depending upon howthe two systems can be integrated, the ePD Shipping Application caneither receive order related data directly from customers using astandardized web page front-end user interface of the ePD ShippingApplication or indirectly through a back-end data interface from theretailer's order processing application. Order data elements such as thefollowing can be written to the Order Header table 1200 when a customerorder is recorded: an Order Identifier (Id), an ePD Retailer Identifier(Id), a Customer Identifier (Id), an Ordering Customer Identifier (Id),an ePD Shipper Identifier (Id), a CDC Identifier (Id), an OrderDate/Time, a Retailer Order Number, a Delivery Type, and a Status. Orderdata elements such as the following, can be written to the Order Detailtable 1202 when a customer order is recorded: Order Id, a SKU, a SKUSize, a Temperature Code, a Quantity, and Status. The values written tothe following fields can be provided by the customer: Customer Id,Ordering Customer Id, ePD Shipper Id (if the retailer offers a choice ofmore than one shipper for ePD delivery), Delivery Type, CDC Id, SKU, andQuantity. If a customer places an order with themselves named as therecipient, Customer Id can be set to the value of the Customer Id andOrdering Customer Id can remain empty. If a customer places an orderhaving someone else as a recipient, Customer Id can be set to therecipient's Customer Id value and Ordering Customer Id can be set to thevalue of the customer's Customer Id. Delivery Type can be a value thatcan be selected by the customer to define whether an order is for ePDdelivery or for traditional delivery to a customer-specified address—thevalue of Delivery Type for an ePD delivery order can be “ePD” (ePackageDepot), while the value for a traditional delivery order can be “LDDH”(local delivery distribution hub). Other values can be written to theorder tables as follows: a unique Order Id can be generated, forexample, by concatenating ePD Retailer Id+Customer Id+order date+a 3digit sequential number (a “sequential number” referred to throughoutthis disclosure can be generated by selecting the value of the field onthe latest record and increasing it by one); ePD Retailer Id can bedefaulted to the pre-defined values of that retailer, as configured inthe retailer's instance of the application; ePD Shipper Id can also bedefaulted to a pre-defined value if the retailer only uses one shipper(it can also be selected by the customer placing the order); OrderDate/Time can be set to the current date/time; Retailer Order Number canbe generated by the retailer's order processing system; Order HeaderStatus can be set to a value such as “open”; Order Detail Status can beset to a value such as “new”; SKU Size and Temperature Code can be setto the values on the retailer's SKU table 1250 for the SKU selected.Each retailer can have its own instance of the SKU table 1250 in itsdatabase, containing SKU's and SKU-related values, which are specific tothat retailer. Fields used to record order-specific or lineitem-specific messages for an order can either be written when an orderis taken or when an order is fulfilled. Those message fields caninclude, but are not limited to, Retailer Message—Order Header andRetailer Message—Packing List on the Order Header table 1200, andRetailer Message—Order Detail on the Order Detail table 1202. Data forthe following additional Order Header 1200 fields can also be capturedfor orders taken by a retailer for traditional delivery: Delivery Name,Delivery Address 1, Delivery Address 2, Delivery City, Delivery State,Delivery Zip.

Orders taken for express delivery to specific addresses are not usuallywritten to the Order Header 1200 and Order Detail 1202 tables of the ePDShipping Application, but can be handled separately by a different orderprocessing application. Express delivery orders can be captureddifferently, because they are normally fulfilled differently. Expressdelivery orders can be usually packed and shipped directly from theretailer's fulfillment warehouse without being sent to an originationRDC 1170. If a shipper does create packages for express delivery ordersin a destination RDC 1180-1, however, those orders can be recorded usingthe Order Header 1200 and Order Detail 1202 tables of the ePD ShippingApplication in the same way as traditional delivery orders.

Following step 1100, cases of items can be picked, labeled, and preparedfor shipment to fulfill the orders in step 1102. Prior to the scheduledePD shipment pick-up, retailers can fulfill all of their customer ordersthat are ready to ship that day, preparing them for shipment. A retailercan pick items in batches at different times throughout the day toprepare the shipment if the shipment proves to be too large to beprepared at one time. There can be several different sorting processeswhich can be employed in the ePD Delivery Process. In one embodiment ofthe invention, a case sorting process can be used. The term “case” willbe referred to throughout this document to describe a box or othercontainer filled with a standard quantity of a particular SKU of aretailer's product. The word “situation” will be used to describedifferent occurrences or situations. Some retailers identify theirproducts by SKU (stock keeping unit) numbers, while others may use otheritem identifiers to identify them. The term “SKU” and common itemidentifier will be used synonymously throughout this disclosure to referto all types of item identifiers, but it should readily be understoodthat the term common item identifier is a more generic term andencompasses SKU. SKU's are well known in the art.

In accordance with this embodiment, a retailer can pick (retrieve fromwarehouse storage locations) items by total SKU quantity rather thanorder by order. Unlike the existing Internet retailer order pickingmethods, the ePD Delivery Process does not require a retailer to sortitems into customer orders or even to break cases to fulfill customerorders. This is because items can be shipped out by the caseload totheir initial destination, the shipper's origination RDC 1170 (theshipper's nearest RDC to the retailer's fulfillment site 1194). Thisefficient shipping process can also reduce the amount of packagingmaterials and available trailer space required for shipment, assumingthat same SKU items can be packed together into cases more efficientlythan different SKU items can be packed into packages for each customer.The ePD Delivery Process can save retailers labor costs, packingmaterial costs, and can reduce the lead-time needed to prepareshipments.

Retailers can use the ePD Shipping Application to drive the fulfillmentsub-process of the ePD Delivery Process. Cases of ordered items can bepicked and shipped within the same sub-process for both ePD deliveryorders to CDC's 1190-1 and for traditional delivery orders tocustomer-specified addresses. Orders specified for express delivery tospecific addresses may be picked and shipped separately from all otherorders depending upon how integrated or separated a shipper's expressshipping process is from its ePD delivery and traditional non-expressdelivery process.

While ePD delivery orders can be delivered to CDC's 1190-1, traditionaldelivery orders can be delivered to local delivery distribution hubs1192-1. A local delivery distribution hub (LDDH) 1192-1 can be afacility within a local market which can receive delivery shipments ofpackages from a destination RDC 1180-1 in much the same way as a CDC1190-1 can receive delivery shipments of bulk delivered packages from adestination RDC 1180-1. Differences between a LDDH 1192-1 and a CDC1190-1 can be in the next steps of each one's associated deliveryprocess. The process of delivering individual packages to individualcustomer specified addresses can involve sorting those packages at aLDDH 1192-1 by zip code-based delivery zones, step 1132, loading thosesorted packages onto delivery vehicles, step 1134, and routing thosevehicles to have drivers deliver packages individually to specificaddresses, step 1136. The steps in the traditional delivery processbeyond delivering packages to a LDDH 1192-1 can be consistent with thetraditional delivery process and are well known in the art. The detailsof the steps prior to and including delivering packages to a LDDH 1192-1are detailed within this disclosure, as they can be similar to andintertwined with the ePD Delivery Process. An LDDH 1192-1 can be by itsnature very different than a CDC 1190-1, but because the sub-processesinvolved in preparing and shipping packages to both CDC's 1190-1 andLDDH's 1192-1 can be the same, both can be identified by a CDC Id.

Retailers can run the ePD Shipping Application's Pick List ReportProgram (310) to create the report used to guide workers through thefulfillment warehouse to pick cases for shipment to the shipper'snearest origination RDC 1170. The following illustrates an exemplaryembodiment that is not intended to limit the scope of the invention. ThePick List Report Program (310) can parse the CDC Id on an Order Headerrecord 1200 to determine a Local Market Id embedded within the CDC Id ofthat CDC 1190-1. It should be noted that references to a “record” inthis disclosure are references to data records in a database table or adata view, unless otherwise noted as data file records or other types ofrecords. The program (310) can use that determined Local Market Id andthe ePD Shipper Id on the Order Header record 1200 to select an RDC Idfrom a RDC-Local Market table 1264, and can update the Order Headerrecord 1200 with the determined Local Market Id and the selected RDC Id.This applies to both delivery orders and traditional delivery orders, asitems for both types of orders can be picked and shipped together. Next,the program (310) can select Order Detail records 1202 having Statusequal to a value such as “new” or “not in stock” and the RDC Id fieldfrom the Order Header records 1200 associated with those Order Detailrecords 1202. It can then sort and group the order information by SKUand RDC Id to create a data view of the information containing the totalquantities of each SKU bound for each destination RDC (for example1180-1, 1180-2, 1180-3, 1180-4, and 1170)—a SKU data view 1204. Dataviews, as referred to throughout this disclosure, can be similar instructure and function to a data table, but the data in the fields of adata view can be derived by selecting and manipulating data from fieldsin one or more data tables. The data in the records of a data view canbe dynamic, meaning that it can change as data changes on the tablesfrom which that data view can be derived. The program (310) can thendivide the total quantities per SKU-RDC Id combination by the standardcase quantity for that SKU, as listed on the SKU table 1250, to createanother view of the data listing the total number of cases and itemsneeded per SKU, per RDC—a Case data view 1206. The remainders of thedivision can be listed as items. For example, if the total quantity ofSKU 123456789 bound for RDC Id AA001=60 and the standard quantity percase for SKU 123456789 is 16, then the Case data view would show SKU:123456789, RDC Id: AA001, Case Quantity: 3, Item Quantity: 12.

The program can use the Case data view 1206 and SKU table 1250 of theePD Shipping Application and item inventory data from the retailer'sinventory management system to create new records on a Case table 1208.The value of a Case Id field on newly created Case records 1208 can beset to a unique alphanumeric descriptor generated for each labeled case,for example, by concatenating ePD Retailer Id+date picked (currentdate)+a sequential 6 digit number. The ePD Retailer Id on each new Caserecord 1208 can be set to the value of the current retailer asconfigured within the retailer's instance of the ePD ShippingApplication. The term “current” will be used throughout this disclosureto refer to the particular instance currently being described for dataand objects for which there can be multiple instances within the ePDDelivery Process. The program (310) can set Status to a value such as“picked” on each new Case record 1208 it creates. As the program (310)compares the Case data view 1206 against the item inventory data in theretailer's inventory management system the program (310) can create anumber of new Case records 1208 equal to the Case Quantity on the Casedata view 1206, with each new record having the RDC Id and SKU values onthose Case data view records 1206 and a Quantity equal to the StandardCase Quantity on the SKU table 1250 for the current SKU. Where the ItemQuantity on a Case data view record 1206 is greater than zero, theprogram (310) can also create one additional new Case record 1208 havingthe current RDC Id and SKU of the current Case data view record 1206 anda Quantity equal to the Item Quantity on the current Case data viewrecord 1206. SKU Size and Temperature Code on the new Case records 1208can be set to the values on the SKU record 1250 corresponding to the SKUon the Case data view record 1206. Partial/Mixed Flag can be set to avalue such as “no” on the new Case records 1208 created for the CaseQuantity value and can be set to a value such as “yes” for the records1208 created for the Item Quantity value. The other Case fields can haveno value when Case records 1208 are first created.

With reference to FIG. 9D, the program (310) may only create new Caserecords 1208 to meet the item quantities that can be found in stock in aretailer's inventory management system, for example, on the exemplaryitem inventory table 1248. Different retailers may use differentinventory management systems, but the minimum data required for the ePDDelivery Process can be to have fields such as the following, accessibleto the ePD Shipping Application: SKU, a Warehouse Location, andQuantity. As the Pick List Report Program (310) creates new Case records1208, it can also update the Status on the Order Detail records 1202,which underlie the Case data view records 1206 from which the Caserecords 1208 can be created. A close relationship exists between theOrder Detail data and Case data. Both sets of data can refer to the samephysical items, and throughout the ePD Delivery Process both sets ofrecords can be updated as the physical cases of items are moved throughthe different steps of the process. Order Detail Status can be updatedto a value such as “pick list—new” or “pick list—back order” on allOrder Detail records 1202 having the SKU and RDC Id corresponding to theCase records 1208 being created, up until the total quantity of all thecreated Case records 1208 for that SKU and RDC Id combination. The valueto which Status can be updated can depend upon its previous value. OrderDetail records 1202 which previously had a Status value such as “new”can be updated to a value such as “pick list—new”, while those whichpreviously had a Status value such as “not in stock” can be updated to avalue such as “pick list—back order”. Where quantities of an ordered SKUare not available in the retailer's item inventory, the Status on OrderDetail records 1202 matching the quantity shortfall can be updated to avalue such as “not in stock”.

Referring to the prior exemplary embodiment, if the retailer had 60 ormore of SKU 123456789 in stock, four records could have been created tohold the data. Each record would have had a unique Case Id. All fourrecords would have had the same ePD Retailer Id, RDC Id, and SKU. Thefirst three records would have had a quantity of 16. The fourth recordwould have had a quantity of 12. The Status field on all Order Detailrecords 1202 having SKU=123456789, Status=“new” or “not in stock” and arelated Order Header record 1200 having RDC Id=“AA001” would have beenupdated to either “pick list—new” or “pick list—back order”. If theretailer's inventory management system had showed less than 60 ofSKU=123456789 in stock, then new Case records 1208 would have beencreated up to the total amount in stock and the Status on the underlyingOrder Detail records 1202 would have been updated to either “picklist—new” or “pick list—back order” only up to the in-stock amount. Theprogram (310) would have attempted to create new Case records 1208 andupdate Order Detail records 1202 for all ordered items by the sequencein which the RDC Id's are sorted with priority given to the Order Detailrecords 1202 which already had a Status of “not in stock”. SelectedOrder Detail records 1202 which were not updated to a Status of either“pick list—new” or “pick list—back order” would have been updated to aStatus of “not in stock”.

After the Case records 1208 get created, the program (310) can readthrough them to create a Pick List Report for all the new Case records1208 (new Case records can be identified by selecting Status equal to avalue such as “picked”). The Pick List Report can be printed on specialpre-sized, peel-off sticker label stock. The report can print one labelfor each case to be picked, sorted first, for example, by warehouselocation, then by SKU, and then by RDC Id. Before printing the report,the program (310) can display the total number of case labels to beprinted and prompt the program user to enter the desired number of pickgroupings. The user can then enter the number of pick groupings intowhich the report will be divided. Typically, workers will break thereport into pick groupings based upon the number of workers pickingitems and a reasonable assessment of the amount of items to be pickedand tracked together. The program (310) can create a new record on aPick Grouping table 1210 for each pick grouping it creates. PickGrouping records 1210 can be created with a Pick Grouping Id formed, forexample, by concatenating ePD Retailer Id+date picked (currentdate)+“PG”+a sequential three digit number. The other fields on the PickGrouping record 1210 can initially be created without values. Theprogram (310) can then print out the report, for example, forcing a pagebreak on each new pick grouping and printing the Pick Grouping Id inboth readable and barcode format at the top of the first page of eachpick grouping above the first case label of that pick grouping. Theprogram (310) can also write the Pick Grouping Id value to the PickGrouping Id field on the Case record 1208 corresponding to each caselabel printed within that pick grouping. As each Case record 1208 getsupdated, the Case Quantity field on the Pick Grouping table can beincremented. The RDC Id printed on a case label is that case'sdestination RDC 1180-1—the RDC from which that case will be processedinto different packages. Initially cases can be shipped to the closestRDC, which can be referred to as the origination RDC 1170. In somesituations the origination RDC 1170 can also be the destination RDC 1170(as depicted in FIG 1A).

Generally a retailer can have one origination RDC 1170 for a particularshipper to which all shipments can be sent. However, if a retailer islocated in a market, which is approximately half-way between two or moreRDC's of a particular shipper (1170 and 1180-2 for example), thatretailer can send shipments for that shipper to more than oneorigination RDC. This can be done to minimize situations where cases areshipped to an origination RDC 1170 in one direction and then transportedfrom that origination RDC 1170 to a destination RDC 1180-2 in theopposite direction. If a retailer regularly prepares shipments for morethan one origination RDC (1170 and 1180-2 continuing with this example),a different customized version of the Pick List Report can be run tocreate the shipment for each origination RDC (1170 and 1180-2 continuingwith this example). Each customized version of the Pick List Report canbe configured to select only the order information containing specifiedRDC Ids. Continuing with the current example, the version of the reportused to build retailer shipments sent to origination RDC 1170 couldinclude all items ordered for CDC's or LDDH's associated withorigination/destination RDC 1170 and destination RDC 1180-4, and thereport used to build retailer shipments sent to origination RDC 1180-2could include all items ordered for CDC's or LDDH's associated withorigination/destination RDC 1180-2, destination RDC 1180-1, anddestination RDC 1180-3. Although each Pick List Report can be used toprepare one shipment to one origination RDC (1170 or 1180-2), a shipmentof cases picked to go to one origination RDC (1170 for example) may needto be split into two or more shipments, bound for that origination RDC1170 at different times, depending upon the amount of available trailerspace on the tractor-trailers bound for that origination RDC 1170. Aretailer shipment can be defined as a group of item cases being shippedfrom one retailer, to one origination RDC 1170, on one trailer.

Referring to FIG. 8, the term “trailer” (202) refers to thecargo-carrying component of a tractor-trailer, which can be detachablefrom the tractor (200) having the engine to move the tractor-trailer.References in this disclosure to shipments of cases or packages beingtransported from one location to another on a trailer (202) ortractor-trailer can also include other non-tractor-trailer vehicleswhich are suitable to carry cargo, or an intermodal shipping combinationusing two or more of the following: a tractor-trailer or other suitablecargo carrying vehicle, a locomotive, a maritime vessel, and anairplane.

A Pick List Report can contain all the cases of items that can be neededto fill all open orders at the time it is printed. The Pick List Reportcan be divided into sections by pick groupings and each worker pickingcases of items to fill open orders can be given one or more sections ofthe report. The Pick List Report can be made up mostly of case labels,with warehouse locations printed to one side of the labels on thereport. The warehouse locations of the cases to be picked can guide oneor more workers through the warehouse in warehouse location sequence. Asa worker arrives at the warehouse location listed on the report, theworker can pick one case matching the SKU on one of the labels on thereport. The worker can then peel the label off the report and place iton the side of the picked case. The worker can continue to pick all thecases listed on the report in this manner, location by location, in thesequence listed on the report.

Most of the labels on the report can be for full case quantities, butthe report can also have labels for partial case quantities. Partialcase labels can be marked, for example, with an asterisk next to thequantity on the label to easily identify a case to which it is affixedas a partial case. There may only be up to one partial case labelprinted per SKU-RDC Id combination. Workers can open a full or existingpartial case to pick the exact number of items listed on a partial caselabel into an empty picking tote container. Partial case labels do nothave to be applied to a case at the time the items get picked, since thecase from which the items can be picked can remain in the warehouselocation. Partial case items can be grouped together by RDC Id andpacked together into boxes or other suitable containers for shipment tothe destination RDC identified by each RDC Id. As the partial case itemsget packed together into mixed-item case boxes, the partial case labelscan be peeled off of the report and placed on the boxes in which thepicked items corresponding to those partial case labels are packed.Boxes containing partial case items of different SKU's packed togethercan have more than one label on them, but each label will have the sameRDC Id.

Each case label can have a readable description containing the followinginformation: Case Id, RDC Id, SKU, a Product Description, and Quantity.The RDC Id can be printed on the label in larger print to allow for easyidentification without close inspection. The Case Id can be printed onthe label, for example, in a barcode format, in addition to regulartext. A character such as an “S” (for single-item case) can also beprinted in large easily readable print, in a distinct area on a caselabel for a case having a Quantity of “1”.

The labeled cases filled with ordered items can be stacked tightly onthe retailer's shipping dock conveyor in a manner similar to how boxeswould be stacked on pallets. The stacked cases can be grouped on thedock conveyor by pick grouping with the front page of the Pick ListReport containing the Pick Grouping Id attached to one of the cases atthe front of the grouped stack of cases. The cases can be stacked tomake use of space as efficiently as possible without extending beyondthe edges of the dock conveyor. For partially filled mixed-item cases,additional packing materials can be used when trying to consolidate thedifferent types of partial case items into mixed-item case boxes.

Turning now to step 1106, tractor-trailers can be used to pickupshipments from retailers. These can include trailers that are emptyafter having completed deliveries to CDC's 1190 or LDDH's 1192 in thelocal market in which the retailer's fulfillment site 1194 is located.The tractor-trailers can pick-up shipments from retailer fulfillmentsites 1194 in that local market before returning to the origination RDC1170 where they might be based. Outbound delivery shipments from an RDC1170 (serving as a destination RDC) and inbound retailer shipments tothat RDC 1170 (the same RDC, serving as an origination RDC) can becoordinated to minimize the need to send empty tractor-trailers from anorigination RDC 1170 to retailer fulfillment sites 1194 to pick-upshipments. Empty tractor-trailers can also be sent from the originationRDC 1170 to retailer fulfillment sites 1194, if needed, to ensureshipments get transported to the RDC 1170 in a timely manner. If aretailer's shipment does not fill the scheduled tractor-trailer'savailable capacity, the tractor-trailer driver can contact theorigination RDC 1170 to determine if there are other retailerfulfillment sites 1194 in the local market from which the driver couldpick up retailer shipments before returning to the origination RDC 1170.

A tractor-trailer driver scheduled to pick up a shipment from a retailercan contact the retailer prior to arriving in order to determine howmuch trailer space is needed for the retailer's shipment. In a situationwhere there is a retailer which ships to more than one origination RDC1170 the driver can let the retailer know which origination RDC (1170 or1180-2 using the prior example) the driver is inquiring about. One ofthe retailer's workers can look at the sides of the shipping dockconveyor where the shipment of cases has been stacked to determine theapproximate load requirement. Dock conveyors can have ruler markings ontheir sides (for example, meters and centimeters on one side, feet andinches on the other) running from front to back. The retailer can reporta full shipment or the length of the shipment if the dock conveyor isless than full. A retailer can have multiple shipments on multiple dockconveyors and can communicate, to the inquiring driver, the total numberof full shipments and/or the total length of any partial shipments ithas prepared. Where the tractor-trailer had already picked up a shipmentfrom another retailer and its driver knows that there will not beadequate space to accommodate the full shipment that the retailer hasprepared, the driver can notify the retailer as to the length of theshipment that can be accommodated. A driver can know the remainingcapacity of the trailer by checking the ruler markings on the sidewallsof the trailer. Upon being notified by the driver that thetractor-trailer picking up the retailer shipment only has a certainremaining capacity, the retailer can make adjustments to the preparedretailer shipment to split it into two if necessary, thereby creating agap on the dock conveyor between the two retailer shipments. Where thedriver is not able to pick up the entire shipment, even when the traileris empty, but the retailer has more than one full shipment prepared, thedriver can contact the origination RDC 1170 to alert the origination RDC1170 of the total amount of trailer space needed to pick up the rest ofthe retailer's shipment(s) considering the portion of the retailershipment that the tractor-trailer can accommodate. The origination RDC1170 can make any necessary scheduling adjustments to send additionaltractor-trailers as needed to pick up any remaining retailershipment(s).

In a further aspect of the invention, a shipper's tractor-trailer canarrive at a retailer's fulfillment site 1194 empty or partially filledwith a shipment previously picked up from another retailer. Uponarrival, a worker, for example, a retailer worker can start a RetailerShipment Program (312) on a workstation or suitably configured computeror terminal running the ePD Shipping Application. The worker can use ahand-held scanner connected to that workstation to scan a barcode ontheir employee identification (id) card and then a barcode on the labelon the back of the trailer door. With reference to FIG. 9B, the RetailerShipment Program (312) can create a Retailer Shipment record 1212 whichcan have exemplary values such as: a Retailer Shipment Id created forexample, by concatenating ePD Retailer Id+current date+a sequentialthree digit number; a Status which can be set to a value such as“in-transit”; an ePD Retailer Id, which can be set to the standardvalues configured for the current retailer; an ePD Shipper Id and anOrigination RDC Id which can either be set to standard values configuredfor the current retailer or selected from lists of values configured forthe current retailer (if the retailer uses more than one shipper and/orships to more than one RDC); a Retailer Employee Id and a Trailer Idthat can be set to the values scanned in by the worker; a RetailerShipping Date/Time that can be set to the current date/time; and allother fields on the Retailer Shipment Record 1212 can be created with novalue or a standard initialized value.

There is shown in FIG. 8, a trailer parked at a Shipping/Receiving DockArea. FIG. 8 shows, tractor 200, trailer 202, trailer conveyor 204,facility exterior wall 231, shipping/receiving dock (bay) door 233,shipping/receiving dock conveyor (extension) 235, and shipping/receivingdock conveyor 236.

Referring to FIG. 8, a tractor-trailer driver can back thetractor-trailer up to the shipping dock of the retailer fulfillment site1194 and open the trailer door. After opening the trailer door, thedriver or a retailer worker can reposition a cargo restraining barrierout of the way, if one is being used to hold a partial shipment inplace. A driver or retailer worker can then start a trailer conveyor(204) in the loading direction. Where there is already a shipment ofcases on the trailer conveyor (204), the cases can remain stationary atthe front end of the trailer (202) as the trailer conveyor (204) movesin the loading direction and pushes them up against the front wall ofthe trailer. A continuous three-section conveyor system can be realizedwhen a conveyor extension (235) at the end of the retailer's dockconveyor can be lowered from its upright vertical position to ahorizontal position which extends from the end of the dock conveyor,through the open loading dock door (233) and trailer door, to the end ofthe trailer conveyor (204) on the floor of the trailer (202). The threeconveyor sections—the dock conveyor, conveyor extension (235), andtrailer conveyor (204)—can be used to facilitate the continuous flow ofcases from the shipping dock into the trailer (202). Based upon theavailability of space on the trailer (202), a worker can determine howmany pick groupings of stacked cases on the dock conveyor can be loadedinto the trailer (202). The worker can scan the Pick Grouping Id barcodeon the Pick List Report page attached to each pick grouping of stackedcases to be loaded onto the trailer (202). As each Pick Grouping Id getsscanned, the Retailer Shipment Program (312) can update its PickGrouping record 1210 with the Retailer Shipment Id of the currentRetailer Shipment record 1212. The program (312) can then update Caserecords 1208 which have that Pick Grouping Id to set Retailer ShipmentId to the current Retailer Shipment Id and Status to a value such as“retailer shipment”. After updating Retailer Shipment Id and Status onthe Case records 1208 associated with a pick grouping, the program (312)can update values such as the Retailer Shipment Id and Status on anumber of Order Detail records 1202 up to the SKU (or item identifier)quantity, which was updated on the Case records 1208.

To determine appropriate Order Detail records 1202 to be updated, theprogram can determine the total quantity across all Case records 1208having a particular SKU that has been updated with the current RetailerShipment Id. The program (312) can determine that quantity by selectingall the records from the Case table 1208 having the current itemidentifier (SKU) and Retailer Shipment Id and calculating the totalquantity for the selected records. It can then select and update OrderDetail records 1202, having the current SKU and a Status such as “picklist—back order”, to set Retailer Shipment Id to the current RetailerShipment Id and Status to a value such as “retailer shipment—backorder”. Where enough Order Detail records 1202 to equal the SKU quantitytotal calculated for the selected Case records 1208, have not beenupdated from the selected Order Detail records 1202 having the currentSKU and a Status such as “pick list—back order”, the program (312) canselect and update Order Detail records 1202, having the current SKU anda Status such as “pick list—new”, to set Retailer Shipment Id to thecurrent Retailer Shipment Id and Status to a value such as “retailershipment—new”. Priority can be given to back orders, since even thoughthe program (312) is only looking at cases which are in stock and havealready been picked, depending upon available trailer space, some of thepicked cases may be delayed until a later retailer shipment.

In updating Order Detail records 1202 with Retailer Shipment Id's, theprogram (312) can make adjustments to an Order Detail record 1202 topartially fill an order, where a selected Order Detail record 1202 has aSKU quantity greater than what can be filled by the cases, which havebeen included in the retailer shipment. If for example, out of the OrderDetail records 1202 having a particular SKU, remaining to be updatedwith a Retailer Shipment Id, the lowest Quantity is two. After assigningRetailer Shipment Id's to other Order Detail records 1202 having thatSKU, there is a remaining difference of only one between the total SKUquantity of Case records 1208 and Order Detail records 1202 with thecurrent Retailer Shipment Id. Since the program (312) can only updateOrder Detail records 1202 for up to a quantity of one, and the lowestremaining Order Detail Quantity is two, the program (312) can attempt topartially fill the order by creating a new Order Detail record 1202 andsplitting the Order Detail Quantity across the new record 1202 and theexisting record 1202. Continuing with the example, the program (312)creates a new Order Detail record 1202 by copying all the values of theexisting record 1202, except for Quantity. Quantity on the new record1202 can be set to the amount, which can be updated with the currentRetailer Shipment Id. Status can be updated to either a value such as“retailer shipment—new” or “retailer shipment—back order” on the newOrder Detail record 1202, depending upon the Status of the existingrecord 1202. Retailer Shipment Id can be updated to the current RetailerShipment Id on the new Order Detail record 1202. Quantity on theexisting record 1202 can be reduced by the Quantity of the new record1202. Status and Retailer Shipment Id on the existing record 1202 arenot changed when the record 1202 is split. After scanning all of thePick Grouping Id's intended to be loaded onto the trailer (202), theworker can start the dock conveyor in the loading direction. The stackedcases can be moved from the dock conveyor, across the conveyor extension(235), and onto the trailer conveyor (204). The trailer conveyor (204)can move the cases toward the front of the trailer (202), up against thetrailer's front wall or the cases of previously loaded shipments. Theworker can stop the dock conveyor when the trailer is filled or theshipment is fully loaded onto the trailer (202). If necessary, the dockconveyor can be switched to the unloading direction to move cases backfrom the conveyor extension (235) to the dock conveyor. The driver orthe retailer worker can stop the trailer conveyor (204) and if thetrailer (202) is not completely filled, the driver or retailer workercan reposition a cargo net or other restrictive barrier to prevent thecases on the trailer (202) from moving. Whenever the trailer (202)cannot accept all the cases of a pick grouping that can be partiallyloaded onto a trailer (202) or if there is still available space toaccommodate more cases on the trailer (202) after the cases of thescanned pick groupings have been loaded, the worker can initiate aRetailer Shipment Adjustments Program (314) to remove or add cases tothe retailer shipment.

The Retailer Shipment Program (312) can have three menu options whichend the program (312). If no adjustments are necessary, the retailerworker can end the Program (312) by selecting for example, a menu optionsuch as “confirm shipment” at the workstation running the program (312).If more cases or pick groupings of cases are to be added to the retailershipment, a menu option such as “add cases” can be selected. To removecases or pick groupings of cases from the retailer shipment, a menuoption such as “remove cases” can be selected. The “confirm shipment”option can simply end the program (312). By selecting either the “addcases” or “remove cases” option, the Retailer Shipment Program (312) canbe terminated and the Retailer Shipment Adjustments Program (314) can beinitiated in either an “add cases” or a “remove cases” mode. Afterinitiating the Retailer Shipment Adjustments Program (314), a worker canfor example, use a hand-held scanner to scan the case labels or PickGrouping Id's of any cases the worker is adding to or removing from theretailer shipment. If adding or removing a mixed-item case having morethan one case label, all the case labels need to be scanned to add orremove that mixed-item case.

The Retailer Shipment Adjustments Program (314) can select the Caserecord 1208 of each scanned Case Id and can delete the value in itsRetailer Shipment Id field and update its Status field to a value suchas “picked” if removing the case. If adding a scanned case, the program(314) can set the value of the Retailer Shipment Id field on the Caserecord 1208 of the scanned case to the value of the current retailershipment and update its Status to a value such as “retailer shipment”.Where a Pick Grouping Id is scanned, the program (314) can select andupdate the Pick Grouping record 1210 and the related Case records 1208having that Pick Grouping Id to add or remove the cases of that pickgrouping to/from the retailer shipment by making the Retailer ShipmentId and Status updates as described for adding or removing a singlescanned case from a retailer shipment. The program (314) can also updateOrder Detail records 1202 to add or remove the current Retailer ShipmentId and update their Status appropriately. Updates made to Order Detailrecords 1202 when adding cases can be done in the same way as they arewhen pick groupings of cases are scanned into a retailer shipment by theRetailer Shipment Program (312), although lesser quantities can beupdated as single cases get scanned. In an example where the possiblevalues of the Status field on Order Detail records 1202 corresponding tothe cases of a retailer shipment are “retailer shipment—new” or“retailer shipment—back order”, the Retailer Shipment AdjustmentsProgram (314) can update Order Detail records 1202 when removing casesby first selecting the ones having a Status of “retailer shipment—new”and the SKU of the scanned case. The program (314) can delete theRetailer Shipment Id value of the selected Order Detail records 1202 andcan update their Status to “pick list—new”. Continuing with thisexample, Order Detail records 1202 having a Status of “retailershipment—back order” can be removed from the retailer shipment onlyafter all Order Detail records 1202 having a Status of “retailershipment—new” for the scanned SKU have already been removed. The program(314) can update the selected Order Detail records 1202 having a Statusof “retailer shipment—backorder” in the same manner as described for theother record update in this example, except that the Status of theselected records 1202 can be set back to “pick list—back order”.

After all the cases and/or pick groupings to be adjusted to or from theretailer shipment are scanned, a suitable menu option such as the“confirm shipment” menu option of the Retailer Shipment AdjustmentsProgram (314) can be selected to terminate the program's (314)operation. When the retailer shipment is confirmed from either theRetailer Shipment Program (312) or the Retailer Shipment AdjustmentsProgram (314), a Retailer Shipment Report can be created to list, forexample, the total number of pick groupings and the total number ofcases associated with the retailer shipment. The Retailer Shipment Idcan be printed at the top of the page, for example, in barcode format aswell as in readable format. The driver can then obtain that printedreport, close the trailer door, and proceed to an origination RDC 1170if the trailer (202) is full or to another retailer fulfillment site1194 in the local market if the driver still has trailer spaceavailable.

The Retailer Shipment Program (312) can create an association betweenspecific cases and a specific retailer shipment when it writes theRetailer Shipment Id of a retailer shipment to Case records 1208.Associating specific cases with a specific retailer shipment can allowthe shipper and the retailer to track the location of ordered items atthe case level from the retailer fulfillment site 1194 to a specifictractor-trailer to an origination RDC 1170. It can also give theretailer visibility to which cases remain on its shipping dock. The ePDShipping Application can also provide visibility to which lines of anorder have been picked and remain on the shipping dock, and which oneshave been picked and shipped on a specific tractor-trailer. Thus, theapplication can provide visibility to the item quantities sent within aparticular retailer shipment through both the Case records 1208 and theOrder Detail records 1202 associated with that retailer's shipment.Since each can provide a different view of the same shipped items, thetotal item quantity across all the Case records 1208 for any given SKUwithin a retailer shipment is equal to the total item quantity acrossall the Order Detail records 1202 for that same SKU within that sameretailer shipment. Although in total their item quantities movetogether, there is no direct link between Case records 1208 and OrderDetail records 1202. There is no direct link, because an Order Detailrecord 1202 is not tied to any one specific case. Because Order Detailrecords 1202 do not have to be tied to specific cases (and specific Caserecords 1208), the RDC sorting process is more flexible and requiresless effort than it would if it required RDC workers to find specificcases to fill specific orders.

There is shown in FIG. 3, an exemplary embodiment of a RegionalDistribution Center (RDC). The regional distribution center can comprisethe following entities: Local market receiving dock (bay) door 12, Localmarket receiving dock conveyor 14, RDC sort conveyor—inbound section 16,RDC sort conveyor—outbound section 18, RDC sort conveyor—overflowsection 20, RDC shipping dock conveyor 22, Local market sort conveyor24, Intermodal rail yard 25, Intermodal railcar loading equipment 26,RDC inbound receiving dock (bay) door 31, RDC inbound receiving dockconveyor 32, RDC inbound conveyor—unloading section 34, RDC inboundconveyor—local market connection 36, RDC inbound conveyor—case divertingsection 38, RDC inbound conveyor—overflow section 40, CDC sort conveyor42, CDC packing station conveyor 44, CDC packing station 45, Packageconveyor—left-side feed 46A, Package conveyor—right-side feed 46B,Package conveyor—merging section 46C, Package conveyor—outbound section46D, Package conveyor—overflow section 46E, CDC Package conveyor—CDCfeed 47A, CDC Package conveyor—local market feed 47B, Local marketshipping dock conveyor 48, Local market shipping dock (bay) door 50, RDCshipping dock (bay) door 52, Bubble wrap bag production machine 58, RDCWorker Entrance door 60.

In a further aspect of the invention, inbound shipments from a pluralityof retailers can be received for processing at an origination RDC 1170as shown in step 1110. Referring to FIG. 3 in addition to FIG. 1, FIG. 2and FIG. 8, a driver can back the tractor-trailer up to a local marketreceiving dock bay (12) at the origination RDC 1170 and signal to letRDC workers know that a shipment has arrived. Upon arrival at theorigination RDC 1170, a worker can open a receiving dock door, scan abarcode on their employee identification (id) card, scan the barcode onthe trailer label (located on the trailer door of a trailer (202)), andthen open the trailer door. The worker can use a suitable barcodereading device such as a hand-held barcode scanner or a hands-freebarcode scanner. A hands-free barcode scanner, as referenced throughoutthis disclosure, can include, but is not limited to barcode scanningdevices in which the barcode scanning mechanism can be mounted onto aring, glove, or bracelet. The barcode scanner used by the RDC worker cancommunicate via a wired and/or wireless access methodology with aworkstation that can be connected to a RDC server running an instance ofa Receive Retailer Shipment Program (316) of the current RDC's instanceof the ePD Shipping Application. The programs of the ePD ShippingApplication and an ePD Delivery Application, as referenced in describingthe steps performed at a RDC (1110 through 1124) throughout thisdisclosure, can run on either a workstation connected to the RDC serveror on the RDC server. After opening the trailer door, the worker canreposition a cargo net (or cargo restraining barrier) to one side of thetrailer (202), if there is one holding the cases on the trailer (202) inplace. The worker can then lower a conveyor extension (235) of a localmarket receiving dock conveyor (14) from its raised vertical position toits horizontal loading position to bridge the gap between the localmarket receiving dock conveyor (14) and the trailer conveyor (204). Theworker can start the local market receiving dock conveyor (14)(including its conveyor extension (235)) in the unloading direction, andcan then start the trailer conveyor (204) in the unloading direction.The retailer shipments of cases can flow from the trailer conveyor(204), across the conveyor extension (235), and onto the local marketreceiving dock conveyor (14).

The RDC worker unloading the current retailer shipments can receive allthe Retailer Shipment Reports from the tractor-trailer driver, for theretailer shipments on the trailer (202). The worker can scan theRetailer Shipment Id barcode at the top of each report. By scanning theRetailer Shipment Id's on the Retailer Shipment Reports after scanningtheir Employee Id and the Trailer Id, the worker can accept all theretailer shipments and associated cases arriving on that trailer (202)into the current origination RDC 1170, by initiating the ReceiveRetailer Shipment Program (316) to add a new record to a RetailerShipment Receiving table 1214 for each Retailer Shipment Id scanned.Each new Retailer Shipment Receiving record 1214 can have the scannedRetailer Shipment Id, Employee Id, and Trailer Id values. Each record1214 can also be created with a Status field value such as “received”and an ePD Shipper Id field that can be set to the value of the shipperoperating the current origination RDC 1170. After creating each RetailerShipment Receiving record 1214, the program (316) can search a Retailertable 1246 for the record having the ePD Retailer Id embedded in theRetailer Shipment Id of the current Retailer Shipment Receiving record1214. Data in a Connection Script field of that retailer's record 1246can be read and used to establish a remote connection to a serverrunning that retailer's instance of the ePD Shipping Application.

The program (316) can select the record, having the current RetailerShipment Id on the Retailer Shipment table 1212 in the database of theretailer's instance of the ePD Shipping Application and make thefollowing updates to it: Status can be set to a suitable value such as“received”; Retailer Shipment Arrival Date/Time can be set to thecurrent date/time; and Receiving Employee Id can be set to the EmployeeId on the current Retailer Shipment Receiving record 1214. The program(316) can then copy the Retailer Shipment record 1212 from the databaseof retailer's instance of the application to the database of theorigination RDC's 1170 instance of the application. The program (316)can select the Case records 1208 and Order Detail records 1202 in theretailer's database instance having the current Retailer Shipment Id andcan update the Status field on both sets of records to a value such aseither “origination RDC” or “destination RDC”. Case record Status can beupdated to “destination RDC” if the RDC Id on the Case record 1208 isthe one for the current origination RDC 1170. Order Detail record Statuscan be updated to “destination RDC” if the related Order Header record1200 has the RDC Id of the current origination RDC 1170. The Status onall other Case records 1208 and Order Detail records 1202 can be updatedto “origination RDC”. After making the Status updates, the program (316)can copy the selected Case records 1208 and Order Detail records 1202 tothe RDC's database instance along with the Order Header records 1200associated with the selected Order Detail records 1202.

After all the cases get loaded onto the local market receiving dockconveyor (14), the worker can stop the trailer conveyor (204) and canclose the trailer door. The local market receiving dock conveyor (14)can run along the floor of an origination RDC 1170, from the edge oflocal market receiving dock door (12) to the edge of the inbound sectionof the RDC sort conveyor (16). Although certain hardware, software,types of personnel, and functions may be described as being in either anorigination RDC 1170 or a destination RDC (1180-1 or others), each RDCcan have the same hardware, software, types of personnel, and functionsas another RDC, as each one can serve as an origination RDC for someitems and a destination RDC for some items. Hence, such description isnot intended to be a limitation on the system and method. When the localmarket receiving dock conveyor (14) is moving in the unloadingdirection, it can carry cases unloaded from a trailer (202) onto theinbound section of the RDC sort conveyor (16). The inbound section ofthe RDC sort conveyor (16) can run along the floor of an origination RDC1170 perpendicular to all the local market receiving dock conveyors (14)and the outbound section of the RDC sort conveyor (18) can runperpendicular to all the RDC shipping dock conveyors (22). Each sectionof the RDC sort conveyor (16, 18 & 20) can be left continually runningas appropriate to handle the activity on any of the dock conveyors (14and 22) adjacent to it. After all the cases unloaded from the trailer(202) have been moved from the dock conveyor (14) onto the inboundsection of the RDC sort conveyor (16), the worker can stop the dockconveyor (14). The worker may need to stop and restart the dock conveyor(14) to coordinate the flow of cases from the dock conveyor (14) intothe flow of cases already on the RDC sort conveyor (16).

In a further aspect of the invention, items received at the originationRDC 1170 can be sorted by RDC Id in step 112. Cases arriving at theorigination RDC 1170 on a bulk carrier such as a tractor-trailer can bemoved from the local market receiving dock conveyor (14) onto theinbound section of the RDC sort conveyor (16). The RDC sort conveyor canbe made up of different conveyor belt sections, for example an inboundsection (16), an outbound section (18), and an overflow section (20).The inbound section of the conveyor (16) can run along the floorperpendicular to and at the same height as the local market receivingdock conveyors (14). The inbound section of the RDC sort conveyor (16)can begin at the first local market receiving dock conveyor (14),continue along the floor past all the local market receiving dockconveyors (14) and end adjacent to the outbound section of the RDC sortconveyor (18). The inbound section of the conveyor (16) can always movein the same direction—toward the outbound section (18). The stackedcases of retailer shipments that enter the RDC on tractor-trailers canflow from the inbound section (16) to the outbound section of the RDCsort conveyor (18). There can be several possible embodiments of how thestacked cases of a retailer shipment can be broken down during sortingin an origination RDC 1170. In one exemplary embodiment, the stackedcases can be broken down into unstacked cases on the inbound section ofthe RDC sort conveyor (16) by one or more workers or by case sortingequipment prior to those cases moving to the outbound section of the RDCsort conveyor (18). Continuing with this exemplary embodiment, theoutbound section of the RDC sort conveyor (18) can gradually rise fromthe floor to reach approximately the height of a typical worker's waist.In a different exemplary embodiment, the outbound section of the RDCsort conveyor (18) can run along the floor and the stacked cases ofretailer shipments can be broken down by workers performing the RDC casesort 1112 on the outbound section of the RDC sort conveyor (18).

Workers performing the RDC case sort step 1112 can look at the RDC Idprinted on the case label of each case passing by on the outboundsection of the RDC sort conveyor (18). The workers can be organized intoteams by the destination RDC (for example 1180-1, 1180-2, 1180-3,1180-4, and/or 1170) for which they can be preparing RDC shipments.Members of each team can pick the cases marked for their destination RDC(for example 1180-1) from the conveyor (18) and move them onto the RDCshipping dock conveyor (22) upon which they can be preparing their RDCshipment. In the motion to move a case from the RDC sort conveyor (18)to the RDC shipping dock conveyor (22), a worker can scan the label onthe picked case, for example, by moving it across a stationary barcodescanner associated with that RDC shipping dock conveyor (22). Thestationary scanner can be located next to the dock conveyor (22).Scanners are well known in the art. Prior to scanning the first case ofa new shipment, workers on the team can scan their employee id card tosign on as an author/sorter of that RDC shipment. Upon scanning thefirst case of a new shipment, a RDC Shipment Program (318) of the ePDShipping Application can create a new record on a RDC Shipment table1216. The program (318) can select the Case record 1208 of the scannedcase using for example, the scanned Case Id and can update the new RDCShipment record 1216 fields such as: a RDC Shipment Id that can be setto a unique value generated by concatenating for example, the RDC Id ofthe current RDC 1170 (the origination RDC)+the current date+a sequential5 digit number; a Status that can be set to a value such as “new”; anePD Shipper Id that can be set to the value of the current shipper; anOrigination RDC Id that can be set to the value of the current RDC 1170;a RDC Shipping Dock Id that can be set to the value of a RDC shippingdock (52) (the one at which the current RDC shipment is being created; aDestination RDC Id that can be set to the RDC Id value on the selectedCase record 1208; a plurality of Employee Id fields that can be set tothe values scanned in from the employee id cards (for example, EmployeeId #1 can be set to the first employee id card scanned and Employee Id#2 can be set to the second employee id card scanned, etc.); and allother fields can be created with a null value or no value. The program(318) can also write the RDC Shipment Id of the newly created RDCShipment record 1216 to the RDC Shipment Id field on the Case record1208 of the scanned case.

The teams of RDC workers can continue to pick, scan, and load cases fromthe conveyor (18) onto the dock conveyor (22) until a full RDC shipmentis compiled. A full RDC shipment can be compiled when the cases on thedock conveyor (22) are stacked up as high as the shipment height limit,which can be marked on both sides of the shipping dock door opening(52), as wide as can fit between the side edges of the dock conveyor(22), and as long as can fit between the dock conveyor extension againstwhich the cases can be pressed up at the dock conveyor's (22) front edgeand the shipment limit marking toward the back end of the dock conveyor(22). While workers are building the RDC shipment, scanning each casepicked from the outbound section of the RDC sort conveyor (18), the RDCShipment Program (318) can be validating that the RDC Id associated witheach scanned case matches the RDC Id of the current RDC Shipment record1216 and the first case scanned. If the scanned case is valid, theprogram (318) can update the Case record 1208 setting Status to a valuesuch as “RDC shipment” and RDC Shipment Id to the value of the currentRDC shipment. If the scanned case does not pass the validation, theprogram (318) can signal an error, for example, by sounding an errortone and lighting up a warning light/LED on the scanner to alert theworker that the Case record 1208 of the scanned case has not beenupdated and that the scanned case should not be loaded onto the dockconveyor (22) as part of the current RDC shipment. If an error wassignaled, the worker can react to it by returning the case causing theerror back to the outbound section of the RDC sort conveyor (18).

When the team has finished building the shipment, a worker can scan acommand barcode such as “complete shipment” on, for example, his/heraction command card by running it across the stationary barcode scanner.The “complete shipment” command can trigger the RDC Shipment Program(318) to take certain actions. These can include, but are not limitedto, the following. First, it can update the RDC Shipment record 1216 bysetting Status to a value such as “ready to ship” and RDC Shipment PrepDate/Time to the current date/time. Second, it can associate selectedOrder Detail records 1202 to the current RDC shipment by updating theirStatus to a value such as “RDC shipment” and updating their RDC ShipmentId to the value of the current RDC shipment. The program (318) canselect the Order Detail records 1202 in a manner that can be similar tothe way as the Retailer Shipment Program (312) did when it selectedOrder Detail records 1202 to associate them with a retailer shipment.The team of workers can then proceed to another RDC shipping dockconveyor (22) to start a new RDC shipment for the same destination RDC(for example 1180-1). Alternately, separate teams could be working inparallel to create separate RDC shipments for one destination RDC (forexample 1180-1) at the same time, instead of only having one team perdestination RDC (for example 1180-1).

Referring now to FIG. 1A in addition to FIG. 2 and FIG. 3 as anotherillustrative example of the embodiment, one of the RDC sorting teams canbe responsible for moving cases bound for the current RDC 1170, servingas both an origination RDC and a destination RDC for those cases ofitems from the RDC sort conveyor (18) to a local market sort conveyor(24). The team members of the current origination/destination RDC 1170can be stationed between the RDC sort conveyor (18) and the local marketsort conveyor (24), past the last RDC shipping dock conveyor (22), wherethe end of the outbound section of the RDC sort conveyor (18) ends andthe overflow section of the RDC sort conveyor (20) begins. The RDCworkers on this team can pick cases marked for the currentorigination/destination RDC 1170 and place them onto the local marketsort conveyor (24).

If any cases were picked and placed onto the local market sort conveyor(24) by mistake (such as a case bound for a different destination RDC1180-4 for example), the team of workers picking cases for the currentRDC can notice those cases moving by them on the local market sortconveyor (24) with an indicator, such as a RDC sort return marker forexample, placed on top of them. Upon seeing a case on the local marketsort conveyor (24) having a RDC sort return marker, a worker pickingcases for the current origination/destination RDC 1170 can pick thecase, remove its RDC sort return marker, and place the case on theoverflow section of the RDC sort conveyor (20). The worker can also flipthe RDC sort return marker over and place it back on the local marketsort conveyor (24). RDC sort return markers can have a descriptor suchas “RDC sort” printed on one side and a Local Market Id printed on theother. The Local Market Id printed on each marker can correspond to thelocal market for which the worker who identified the case picking erroris working within the local market sort 1118. The circumstances ofcatching this type of error are discussed later in this description whenthe local market sort step 1118 is described.

The overflow section of the RDC conveyor (20) can be used to allow casesthat are not picked by any of the teams to circle back around to theoutbound section of the RDC sort conveyor (18) and pass by those teamsagain until they can be picked.

Now referring back to FIG. 1 along with FIG. 2, and FIG. 3, in a furtheraspect of the invention, cases of items resulting from the RDC sortingstep 1112 can then be shipped to other destination RDC's (such as RDC1180-1, RDC 1180-2, RDC 1180-3 or RDC 1180-4) as shown in step 1114. TheRDC shipments which have been created by the RDC sort teams can sit onthe RDC shipping dock conveyors (22) awaiting the arrival of emptydrayage tractor-trailers from an intermodal rail yard (25) used by thecurrent origination RDC 1170. Drayage tractor-trailers can normallyarrive from the intermodal rail yard (25) with trailers full of cases ofinbound RDC shipments sent via locomotive freight from other originationRDC's (for example 1180-1, 1180-2, 1180-3, and/or 1180-4) to the currentdestination RDC 1170. Although FIG. 1 shows the current RDC 1170 asbeing the origination RDC and another RDC 1180-1 as being a destinationRDC, it should readily be understood that for purposes of receiving aRDC shipment from other RDC's, the current RDC 1170 can be considered adestination RDC and each RDC sending a RDC shipment can be consideredthe origination RDC for that shipment. Alternatively, thesetractor-trailers can be long-haul tractor-trailers or other suitablecargo carrying vehicles and can arrive at the current RDC 1170, with orwithout cargo, directly from other RDC's (for example 1180-1, 1180-2,11803, and/or 1180-4), from a local market, from an airport, or from aseaport. After inbound RDC shipments on these tractor-trailers areunloaded into the current RDC 1170, the drayage tractor-trailers can bemoved from a RDC inbound receiving dock (31) to one of the RDC shippingdocks (52). Each RDC shipping dock (52) can be designated to ship to aparticular destination RDC (for example 1180-1). An empty drayagetractor-trailer can arrive at a particular RDC shipping dock (22) basedupon factors for example, when cargo trains are scheduled to leave forparticular destination RDC's. Referring now to FIG. 8 in addition toFIG. 3, when an empty tractor-trailer does back into one of the RDCshipping docks (52), a worker such as one of the RDC sort team workerscan load the prepared RDC shipment onto the empty trailer (202) bylowering the RDC shipping dock conveyor extension (235) into the loadingposition (horizontal), initiating the trailer conveyor (204) in theloading direction, and then initiating the RDC shipping dock conveyor(22) in the loading direction. The cases stacked on the RDC shippingdock conveyor (22) can move across the dock conveyor (22) and itsconveyor extension (235) and onto the trailer conveyor (204).

After the shipment has been moved onto the trailer (202), the RDC workercan stop the conveyors, reposition the conveyor extension (235) to theshipment preparation position (vertical), and close the trailer door.The worker can initiate a RDC Shipment Loading Program (320) of the ePDShipping Application, for example by, using a hand-held or hands-freebarcode scanner to scan the barcode on their employee id card, scan aRDC Shipping Dock Id barcode, located on a label on the side of the RDCshipping dock door (52), and scan the Trailer Id barcode, located on alabel on the back of the trailer door. The RDC Shipment Loading Program(320) can select the RDC Shipment record 1216 by searching for a recordhaving the scanned RDC Shipping Dock Id and a Status such as “ready toship”. It can then update the selected RDC Shipment record 1216, settingits Status field to a value such as “on trailer” and writing the scannedEmployee Id to a Trailer Loading Employee Id field, the scanned TrailerId to a Trailer Id field, and the current date/time to the RDC ShipmentTrailer Date/Time field. By updating the RDC Shipment record 1216 with adifferent Status and associating it with a specific trailer, the RDCShipment Loading Program (320) can associate the Case records 1208 andOrder Detail records 1202 which make up that RDC shipment with thattrailer (202). The Case records 1208 and Order Detail records 1202 arenot actually updated by the program (320), but for the time that theyhave a Status such as “RDC shipment” and the RDC Shipment Id associatedwith that RDC shipment, they are associated with and thus can beaffected by updates to the Status of that RDC Shipment record 1216.

The RDC Shipment Loading Program (320) can also access the server of theRDC shipment's destination RDC 1180-1 through a dial-up connection or adedicated wide area network (WAN) and can create a new record on the RDCShipment Receiving table 1218 from the current RDC Shipment record 1216,by copying fields such as the following: RDC Shipment Id, ePD ShipperId, Origination RDC Id, Destination RDC Id, and Trailer Id. It can setthe Status on the newly created RDC Shipment Receiving record 1218 to avalue such as “new”.

In an illustrative embodiment, a driver of a drayage tractor-trailerscan transport a RDC shipment to the current RDC's intermodal rail yard(25). The intermodal rail yard (25) may not be as close to the RDC asshown in FIG. 3. The driver can position their tractor-trailer nearintermodal railcar loading equipment (26) and can detach the trailer(202) of the tractor-trailer from its tractor (200). A worker at thecurrent RDC's intermodal rail yard (25) can use the intermodal railcarloading equipment (26) to lift the trailer up and onto an empty flatbedrail car of a cargo train. Once the trailer containing the RDC shipmentis loaded onto the train, a worker at the intermodal rail yard caninitiate a Train Loading Program (322) of the ePD Shipping Applicationat a workstation or terminal, which can be located in an office at therail yard (25). The worker can enter the Carrier Id of the current trainon the workstation's keyboard and can use a wireless hand-held orhands-free scanner to scan their employee id card. The worker can thentake the wireless scanner out to the train and scan the trailer label ofeach trailer loaded onto the train. The Train Loading Program (322) canselect the RDC Shipment record 1216 of each RDC shipment loaded on thetrain by searching for the record with the scanned Trailer Id value anda Status such as “on trailer”. The program (322) can update the selectedrecord, setting its fields to values such as setting Status to, forexample, “on train”, Carrier Id to the entered value for the currenttrain, Train Loading Employee Id to the scanned Employee Id, and RDCShipment Train Date/Time to the current date/time.

A cargo train arriving at a RDC's intermodal rail yard (25) may be onethat is scheduled to pick-up outbound shipments going to another RDC1180-1 (which can serve as a destination RDC in the rail yard (25) ofRDC 1170, continuing with the illustrative example depicted in FIG. 1),one that is scheduled to deliver inbound shipments from another RDC 1170(which can serve as an origination RDC in the rail yard (25) of RDC1180-1, continuing with the illustrative example depicted in FIG. 1), orone that is scheduled to do both (for example, the cargo train bringingan inbound RDC shipment to the rail yard (25) of RDC 1180-1 can thenpick up one or more RDC shipments bound for another RDC, for example RDC1180-3). In one embodiment, cargo trains can unload trailers, containingRDC shipments coming from other origination RDC's (for example 1180-2),off of rail cars and then load trailers, containing RDC shipments boundfor other destination RDC's (for example 1180-4), onto the rail carswhich have just been emptied. In other embodiments, tractor-trailers orother suitable cargo carrying vehicles can transport RDC shipments froman origination RDC 1170 directly to another RDC 1180-1, or can transfera trailer or the contents of a trailer to a cargo airplane at anairport, or a cargo vessel at a seaport.

In step 1116, items in cases can be received from other originationRDC's 1170 (continuing with the illustrative example depicted in FIG. 1)at a destination RDC 1180-1. In an illustrative embodiment, a carrier,such as a cargo train, can arrive at a RDC's intermodal rail yard (25)making a scheduled stop to deliver inbound shipments coming from anotherRDC 1170 (which can serve as an origination RDC for that RDC shipment).Workers can use intermodal railcar loading equipment (26) to lifttrailers off of flatbed rail cars and onto the ground in an unloadingarea. Drivers of drayage tractor-trailers or workers at the rail yard(25), which may have previously detached their trailers to be loadedonto the current cargo train or another cargo train, can attach theirtractors to one of the trailers unloaded from the current train. Thedrivers can then transport trailers to the destination RDC 1180-1,backing them into a RDC inbound receiving dock bay (31).

Inbound RDC shipments can be physically unloaded from trailers into thedestination RDC 1180-1 in the same manner as inbound Retailer shipments,except that cases can be moved from a RDC inbound receiving dockconveyor (32) to the unloading section of a RDC inbound conveyor (34),instead of being moved from a local market receiving dock conveyor (14)to the inbound section of the RDC sort conveyor (16). The end result ofunloading RDC shipments into the destination RDC 1180-1 can be thatcases from one or more other RDC's (1170 continuing with theillustrative example depicted in FIG. 1) are on the unloading section ofthe RDC inbound conveyor (34) and the tractor-trailers which carriedthose cases sit empty at RDC inbound receiving dock bays (31).

To receive a RDC shipment, a worker at the destination RDC 1180-1 canscan, for example, his/her employee id card, the trailer label of thetrailer in which the RDC shipment arrived, and a case label on any oneof the cases unloaded from the trailer. These actions can initiate aReceive RDC Shipment Program (324) of an instance of the ePD ShippingApplication of the current RDC 1180-1. The Receive RDC Shipment Program(324) can search a database table, such as the RDC Shipment Receivingtable 1218, for a record having the scanned Trailer Id and a Status suchas “new”. An Origination RDC Id value can be read from the selectedrecord 1218 and can be used to search a RDC table 1258 for a recordhaving that value in its RDC Id field. The Receive RDC Shipment Program(324) can then read a RDC Server Connection Script value from theselected RDC record 1258 and can use that information to establish aremote connection to the RDC server of the RDC shipment's originationRDC (1170 continuing with the illustrative example depicted in FIG. 1).Alternatively, the RDC Server Connection Script can be used to point toone of several RDC servers where a dedicated WAN can be used to link theservers of a shipper's RDC's. After establishing the remote connection,the Receive RDC Shipment Program (324) can validate that the Case record1208 of the scanned Case Id on the origination RDC's 1170 server has thesame RDC Shipment Id as the RDC Shipment Receiving record 1218 selectedfrom the database on the current destination RDC's 1180-1 server usingthe scanned Trailer Id. This optional step can be done to validate thatthe case and the trailer on which it was carried are both associatedwith the same RDC Shipment Id. After such optional validation step issuccessfully completed, the Receive RDC Shipment Program (324) can usethe RDC Shipment Id from the selected RDC Shipment Receiving record 1218to select the RDC Shipment record 1216, in the database on theorigination RDC's 1170 server, corresponding to the current RDCshipment. The program (324) can update the Status field to a value suchas “received” and can write the scanned Employee Id to a ReceivingEmployee Id field on both the RDC Shipment record 1216 selected on theorigination RDC's 1170 server and on the RDC Shipment Receiving record1218 selected on the current destination RDC's 1180-1 server. Theprogram (324) can also write the current date/time to the RDC ShipmentArrival Date/Time on the RDC Shipment record 1216 selected on theorigination RDC's 1170 server. The Receive RDC Shipment Program (324)can also select all the Case records 1208 and Order Detail records 1202on the origination RDC's 1170 server having the current RDC Shipment Id,update their Status to a value such as “destination RDC”, and move therecords (1208 and 1202) from the origination RDC's 1170 server to thecurrent destination RDC 1180-1 server. When moving the Order Detailrecords 1202, the program (324) can also select and copy their relatedOrder Header records 1200. Order Header records 1200 can be copiedinstead of moved, because there can be situations when some Order Detailrecords 1202 of an order are moved while others for that order remain onthe origination RDC's 1170 database. By copying Order Header records1200 instead of moving them, Order Detail records 1202 which remain onan origination RDC's 1170 database, and have related Order Headerrecords 1200 which were copied to a destination RDC 1180-1 database,will still have a copy of their related Order Header record 1200 on theorigination RDC's 1170 database. After the program (324) copies theOrder Header records 1200, it can search the origination RDC's 1170database for Order Header records 1200 which no longer have relatedOrder Detail records 1202 and delete them.

After the cases of the inbound RDC shipment have been moved from thetrailer conveyor to the RDC inbound receiving dock conveyor (32) andonto the unloading section of the RDC inbound conveyor (34), they maycontinue to travel around the RDC inbound conveyor, for example in aclockwise direction from the unloading section (34), onto an overflowsection of the RDC inbound conveyor (40) and back onto the unloadingsection (34). The cases can move in this circular holding pattern, untila RDC inbound conveyor case diverting section (38) can be moved into adiverting position. In the exemplary conveyor system illustrated, thecase diverting conveyor section (38) can normally be at rest, lockedinto an overflow position on the outside edge of the unloading conveyorsection (34). To redirect the flow of cases from circling around the RDCinbound conveyor (34, 40), a worker at the destination RDC 1180-1 canrelease a locking pin on the case diverting conveyor section (38) torelease it from an overflow position. The worker can then pivot the casediverting conveyor section (38) to slide it across and over top of theunloading conveyor section (34) and lock it into the diverting positionby sliding its locking pin into place in a locking slot on the insideedge of the unloading conveyor section (34). When locked into thediverting position, the curved-shaped case diverting conveyor section(38) can intercept the flow of cases from the unloading section (34) andredirect them to a local market connection section (36). The localmarket connection section (36) of the RDC inbound conveyor can movecases onto the local market sort conveyor (24). Alternately, in anotherembodiment, automated sorting equipment can be used to direct the flowof cases from the unloading section of the RDC inbound conveyor (34) tothe local market sort conveyor (24).

The local market connection section of the conveyor (36) can be locatedon an incline to facilitate the movement of cases from the casediverting conveyor section (38), starting at the same height as thefloor level unloading conveyor section (34) up to a raised level of thelocal market sort conveyor (24). Workers at the destination RDC 1180-1can break down the stacked cases of a RDC shipment to a level that isone case high before using the diverting conveyor section (38) to movecases from the RDC inbound conveyor (34) up onto the local market sortconveyor (24). Generally, a worker at the destination RDC 1180-1 can usethe diverting conveyor section (38) to move cases from the RDC inboundconveyor up onto the local market sort conveyor (24) as soon as possibleafter the cases have been broken down. If space is unavailable on thelocal market sort conveyor (24), however, the flow of cases can be leftso that it is directed to the overflow section of the RDC inboundconveyor (40).

In a further aspect of the invention, the following steps, consistentwith step 1118, can be used to achieve a local market sort at adestination RDC processing center 1180-1. An ePD Delivery Applicationcan run on a destination RDC's 1180-1 server to facilitate the RDCsub-processes involved in creating packages to fill customer orders foreither ePD delivery to CDC's 1190-1 or traditional delivery to customerspecified addresses. The steps of the ePD Delivery Process previouslydescribed in this illustrative embodiment involved moving cases ofordered items and the Case 1208, Order Header 1200, and Order Detail1202 data records related to those cases to the destination RDC 1180-1in which customer orders will be filled from those cases. At this pointin this illustrative embodiment of the ePD Delivery Process, cases ofordered items, which have been designated for the current destinationRDC 1180-1, have been received by and can be on the local market sortconveyor (24) of the current destination RDC 1180-1. The Case 1208,Order Detail 1202, and Order Header 1200 records related to those casescan be in the database on the current destination RDC's 1180-1 serverand the Status of those Case 1208 and Order Detail records 1202 can be avalue such as “destination RDC”. The database on the destination RDC's1180-1 server can be shared by the ePD Shipping Application, which canbe used to drive the RDC-related steps prior to the local market sortstep 1118, and the ePD Delivery Application, which can be used to drivethe local market sort step 1118 and the remaining RDC-related steps ofthe ePD Delivery Process.

A Local Market Order List data view 1220 can be created from underlyingOrder Header 1200 and Order Detail 1202 tables, for example, byselecting, grouping and subtotaling the Quantity of each SKU from aparticular ePD Retailer Id having a Status such as “destination RDC”, tobe delivered to CDC's 1190-1 or LDDH's 1192-1 associated with aparticular Local Market Id. The Local Market Order List data view 1220can be dynamic, meaning the Quantity subtotal of each ePD RetailerId-SKU combination for a Local Market Id can increase as new OrderHeader 1200 and Order Detail 1202 records are added or can decrease asthe Status of Order Detail records 1202 changes from a value such as“destination RDC” to a value such as “package”. New Order Header 1200and Order Detail 1202 records with a Status such as “destination RDC”can be added as RDC Shipments and Retailer Shipments are received intothe current destination RDC 1180-1. The Status on Order Detail records1202 can be changed from a value such as “destination RDC” to a valuesuch as “package” as packages are created to fill orders.

A Local Market Case Inventory data view 1222 can be created from theunderlying Case table 1208, for example, by selecting, grouping andsubtotaling the Quantity of each SKU (or item identifier) and ePDRetailer Id combination for each Local Market Id on Case records 1208having a Status such as “CDC sort” or “package sort”. Case records 1208can be assigned a Local Market Id when their related cases are scannedand picked from the local market sort conveyor (24) onto a CDC sortconveyor (42). In one embodiment, Case records 1208 of cases on thelocal market sort conveyor (24) do not have Local Market Id's and can betherefore not selected as part of the Local Market Case Inventory dataview 1222.

Workers at the destination RDC 1180-1 who can be stationed between thelocal market sort conveyor (24) and the CDC sort conveyors (42) can forexample, use hands-free barcode scanners to scan case label barcodes oncases moving by them on the local market sort conveyor (24). The barcodescanners can communicate with a workstation running an instance of aLocal Market Sort Program (326) of the ePD Delivery Application via awired or wireless data architecture. The Local Market Sort Program (326)can read the Case table 1208 to determine field values such as, the RDCId, Local Market Id, SKU (item identifier) and ePD Retailer Id of therecord having the Case Id of the scanned case label. The Local MarketSort Program (326) can evaluate the RDC Id value and if it is found thatthe RDC Id value on the Case record 1208 of the scanned case differsfrom the RDC Id of the current destination RDC 1180-1, an alert, such asa double invalid pick warning tone and/or an error warning light, canalert the RDC worker that the scanned case should not be on the localmarket sort conveyor (24). This situation can occur when an error hasbeen made in the RDC sort step 1112, and a case bound for a differentdestination RDC (for example, RDC 1180-2) is mistakenly placed on thelocal market sort conveyor (24) of the current destination RDC 1180-1.Upon hearing the double invalid pick tone alert and/or seeing an errorwarning light, the worker at the destination RDC 1180-1 can place, forexample, a RDC sort return marker on the case, and can let the case passby on the local market sort conveyor (24). The RDC sort return markercan signal other workers performing the local market sort 1118 for otherlocal markets not to scan that case. A worker performing the RDC sort1112 for the current destination RDC 1180-1 can see the case with theRDC sort return marker on it, return the case to the overflow section ofthe RDC sort conveyor (20), flip the RDC sort return marker over, andplace it on the local market sort conveyor (24). The worker who placedthe RDC sort return marker on the case can later see the RDC sort returnmarker with the Local Market Id on it, as it moves around the localmarket sort conveyor (24), and can retrieve it from the conveyor (24).

In the situation where the RDC Id matches the value of the currentdestination RDC 1180-1, the Local Market Sort Program (326) can evaluatethe Local Market Id value. If the Case record 1208 of the scanned casehas no Local Market Id, the scanned case can be processed as a localmarket sort pick—picking a case from the local market sort conveyor (24)to a CDC sort conveyor (42). If the Case record 1208 has the LocalMarket Id of the current CDC sort conveyor (42), the case can beprocessed as a reverse local market sort pick—picking a case to removeit from the current CDC sort conveyor (42) and returning it to the localmarket sort conveyor (24). If the Case record 1208 has a Local Market Idof a different CDC sort conveyor (42), the case can be processed as acorrective local market sort pick—picking a case to remove it from itsprevious CDC sort conveyor (42) to the current CDC sort conveyor (42).

In processing a local market sort pick, the Local Market Sort Program(326) can search for the record on the Local Market Order List data view1220 having the SKU (item identifier) and ePD Retailer Id of the scannedcase, and the Local Market Id associated with the current CDC sortconveyor (42) (the one to which the worker's scanner is communicating).If there is a record 1220 for that SKU (item identifier), ePD RetailerId, and Local Market Id combination, the Local Market Sort Program (326)can compare the Quantity of that record 1220 against the Quantity of itsrelated record on the Local Market Case Inventory data view 1222, ifthere is one (a related record has the same SKU, ePD Retailer Id, andLocal Market Id). The Local Market Sort Program (326) can subtract theLocal Market Case Inventory Quantity (representing the total quantity ofan ePD Retailer Id-SKU combination which has already been picked forthat local market) from the Local Market Order List Quantity(representing the total quantity of an ePD Retailer Id-SKU combinationneeded to fill the open orders for that local market) to determine thenet quantity of that ePD Retailer Id-SKU combination still needed forthat local market. If the Local Market Order List record 1220 does nothave a related Local Market Case Inventory record 1222, the fullquantity of the Local Market Order List record 1220 can be consideredthe net quantity needed. If the net quantity needed of that ePD RetailerId-SKU combination for that local market is greater than zero, the LocalMarket Sort Program (326) can signal the worker to pick the case, forexample, by producing a pick confirmation tone and can assign thescanned case to the local market by writing the Local Market Id of thecurrent CDC sort conveyor (42) into the Local Market Id field of itsCase record 1208 and updating the Status of its Case record 1208 to avalue such as “CDC sort”. Upon hearing the pick confirmation tone (orrecognizing another signal indicating to pick a scanned case), theworker at the destination RDC 1180-1 who scanned the case can pick itfrom the local market sort conveyor (24) and place it on the CDC sortconveyor (42) of the local market for which the worker is working. Wherethere is not a Local Market Order List record 1220 for the current localmarket with the ePD Retailer Id-SKU combination of the scanned case, orwhere there is one, but the Local Market Sort Program (326) determinesthat the net quantity needed for it is less than one, the Local MarketSort Program (326) can signal the worker not to pick the case, forexample, by sounding an invalid pick warning tone. Upon hearing theinvalid pick warning tone (or recognizing another signal indicating notto pick a scanned case), the worker can let the scanned case pass by onthe local market sort conveyor (24).

Many cases picked from the local market sort conveyor (24) onto the CDCsort conveyor (42) for a local market can be used completely to satisfyorders for that local market. In that situation, the quantity of thepicked case can be less than the net quantity needed for that localmarket. As the net quantity of an ePD Retailer Id-SKU combination neededfor a local market decreases toward zero, a picked case can have aquantity greater than the net quantity needed. In that situation, thecase can be picked and the net quantity needed can become negative.After all the item quantities of that ePD Retailer Id-SKU combinationneeded to fill orders for the current local market are picked from thatcase to create packages (as described in the create packages step 1122),a local market sort return marker, for example, can be placed on top ofthe case and the case can be returned to the CDC sort conveyor (42). Asa worker picking cases from the local market sort conveyor (24) sees acase traveling around the CDC sort conveyor (42) with a local marketsort return marker on it, the case can be picked from the conveyor (42),its label can be scanned, and it can be placed on the local market sortconveyor (24). The local market sort return marker can be removed fromthe case, flipped up-side-down, and placed back on the CDC sort conveyor(42). The Local Market Sort Program (326) determining that the Caserecord 1208 of the scanned case already has the Local Market Id of thecurrent CDC sort conveyor (42), can process the scanned case as areverse local market sort pick. In processing the scanned case as areverse local market sort pick, the program (326) can verify that theneeded quantity of the ePD Retailer Id-SKU combination of the scannedcase for the current local market is less than one. If the neededquantity is one or greater, the program (326) can sound, for example, aninvalid pick tone and can refrain from updating the Case record 1208.Upon hearing the invalid pick tone (or recognizing another indicationnot to pick a case), the worker can remove the local market sort returnmarker from the scanned case, place the marker up-side-down on the CDCsort conveyor (42), and let the case remain on the CDC sort conveyor(42). If the Local Market Sort Program (326) finds that the neededquantity is less than one, it can delete the Local Market Id value fromthe Case record 1208 of the scanned case, update the Status of that Caserecord 1208 to a value such as “destination RDC”, and sound, forexample, a pick confirmation tone. Upon hearing the pick confirmationtone (or recognizing another indication that a case should be picked)the worker can pick the case from the CDC sort conveyor (42) and placeit on the local market sort conveyor (24). Changing the Status andremoving the Local Market Id value from the Case record canautomatically reduce the Quantity of the ePD Retailer Id-SKU combinationof the scanned case on the Local Market Case Inventory data view record1222, since the Case record 1208 of the scanned case will no longer beselected by the Local Market Case Inventory data view 1222. By reducingthe Quantity on the Local Market Case Inventory data view record 1222,the net quantity needed for the current local market can increase, sincethe value that the Local Market Sort Program (326) subtracts from theLocal Market Order List data view record 1220 has been reduced. If thefull needed amount of items is picked from the case before the reverselocal market sort pick is processed, the end result of the reverse pickaction can be that a negative needed quantity is increased to zero.

Two situations which can result in a case being physically located onthe local market sort conveyor (24), but logically associated with a CDCsort conveyor (42) will be discussed here as an illustrative example.One situation in which this can occur is when a case is picked from aCDC sort conveyor (42) and placed back on to the local market sortconveyor (24) without being scanned to initiate a reverse local marketsort pick. Another situation in which it can occur is when a case isscanned on the local market sort conveyor (24), but is not physicallypicked from that conveyor (24) to a CDC sort conveyor (42). Where a casehaving a Local Market Id because of either situation is traveling aroundon the local market sort conveyor (24) and is scanned, the Local MarketSort Program (326) can process that case as a corrective local marketsort pick. The Local Market Sort Program (326) can update the LocalMarket Id value on the Case record 1208 of the scanned case to the valueassociated with the current CDC sort conveyor (42) and can sound, forexample, a pick confirmation tone. Upon hearing the pick confirmationtone (or recognizing another indication that a case should be picked),the worker can pick the case from the local market sort conveyor (24)and place it on the CDC sort conveyor (42). In updating the Local MarketId on the Case record 1208 of the scanned case, the Local Market Sortprogram (326) can correct the error that existed in the Local MarketCase Inventory data view 1222 by reducing the Quantity of that ePDRetailer Id-SKU combination for the local market to which it was beingcredited incorrectly. At the same time the Local Market Sort program(326) can correctly update the Local Market Case Inventory data view1222 for the local market of the current CDC sort conveyor (42) as thecase is picked and placed on that conveyor (42).

There can, however, be one exception to the normal result of acorrective local market sort pick. If a case on the local market sortconveyor (24) already has a Status such as “CDC sort” and a Local MarketId, and the worker scanning the case happens to be working at the CDCsort conveyor (42) identified by the same Local Market Id as the one onthe Case record 1208 of the scanned case, then the program (326) canprocess the scanned case as a reverse local market sort pick instead ofa corrective local market sort pick. The Local Market Sort program (326)can remove the Local Market Id from the Case record 1208 and sound, forexample, a pick confirmation as the worker picks the case from the localmarket sort conveyor (24) to the CDC sort conveyor (42). The result ofthis action can actually switch the database from being in error in onedirection to being in error in the opposite direction. Before the casewas scanned and picked, the database could have incorrectly included thequantity of the case in the Local Market Case Inventory data view 1222,when the case was not physically on the CDC sort conveyor (42) of thatlocal market. After the case is scanned and picked, the case canphysically be on the CDC sort conveyor (42), but the database can nolonger be including the quantity of that case in the Local Market CaseInventory data view 1222. This error can be corrected the first time thecase is scanned during a CDC sort processing step 1120.

Most of the cases on the local market sort conveyor (24) can be fullcases containing the standard case quantity for one ePD Retailer Id-SKUcombination or partially picked cases containing less than the standardcase quantity for one ePD Retailer Id-SKU combination. There can besituations where a mixed-item case can be found on the local market sortconveyor (24). Mixed-item cases can contain multiple SKU's from oneretailer. There should be no instance when the SKU's of differentretailers can be found mixed together in the same case within adestination RDC 1180-1. Workers at the destination RDC 1180-1 performingthe local market sort 1118 can break apart mixed-item cases intoseparate cases or other suitable containers containing a quantity of asingle SKU (or item identifier) as they find them on the local marketsort conveyor (24). Mixed-item cases can be easily identified becausethey can have multiple case labels on them. Workers can pick themixed-item cases off of the local market sort conveyor (24) and read theinformation on each of the case labels to determine the quantity of eachSKU (item identifier). They can remove the different item quantitiesfrom the mixed-item case, separating the items of different SKU's intodifferent totes (or other suitable containers). The item quantity of oneof the SKU's can be left in the case. The labels of each different SKUcan be removed from the mixed-item case and placed face-up on top of theitems inside each tote. The label corresponding to the SKU (itemidentifier) remaining in the case can be left on the case. Workers canplace the totes and the case back onto the local market sort conveyor(24) where they can be processed in the same manner as other cases.

After the local market sort 1118 is performed at the destination RDC1180-1, the CDC sort step 1120 can then be performed at the destinationRDC 1180-1. The CDC sort step 1120 can be achieved in a manner similarto the local market sort step 1118. Both include methods for directingcases of items toward a CDC packing station (45) at which packages canbe created from those cases. The local market sort 1118 can be a higherlevel sort used to direct cases which have been designated for thecurrent destination RDC 1180-1 to the CDC sort conveyor (42) of aparticular local market to meet the ePD Retailer Id-SKU quantity levelsneeded to fill the orders bound for that local market. The CDC sort 1120can be a lower level sort used to direct cases which have beendesignated for the current local market to a CDC packing stationconveyor (44) of a particular CDC 1190-1 or LDDH 1192-1 (within thedestination RDC 1180-1) to meet the ePD Retailer Id-SKU quantity levelsneeded to fill the orders bound for that CDC 1190-1 or LDDH 1192-1. ACDC packing station conveyor (44) can be dedicated to creating packagesfor either a LDDH 1192-1 or a CDC 1190-1.

In accordance with the invention, a CDC Order List data view 1224 can becreated from the underlying Order Header 1200 and Order Detail 1202tables by for example, selecting, grouping, and subtotaling the Quantityof each SKU (item identifier), from a particular ePD Retailer Id,having, a Status such as “destination RDC”, to be delivered to aparticular CDC 1190-1 or LDDH 1192-1. The CDC Order List data view 1224can be dynamic, meaning that the Quantity subtotal of each ePD RetailerId-SKU combination for a CDC Id can be increased as new Order Headerrecords 1200 having that CDC Id and their related Order Detail records1202 can be added, or it can be decreased, as the Status of Order Detailrecords 1202 related to Order Header records 1200 having that CDC Idchanges from a value such as “destination RDC” to a value such as“package”. New Order Header 1200 and Order Detail 1202 records with aStatus such as “destination RDC” can be added as RDC Shipments andRetailer Shipments are received into the current destination RDC 1180-1.The Status on Order Detail records 1202 can be changed from a value suchas “destination RDC” to a value such as “package” as packages can becreated to fill orders.

With reference to FIG. 9C, the CDC Case Inventory data view 1226 can becreated from the underlying Case table 1208 by, for example, selecting,grouping and subtotaling the Quantity of each SKU and ePD Retailercombination for each CDC Id on Case records 1208 having a Status such as“package sort”. Case records can be assigned a CDC Id when they getscanned and picked from a CDC sort conveyor (42) onto one of the CDCpacking station conveyors (44).

Workers stationed between a CDC sort conveyor (42) and a CDC packingstation conveyor (44) at the destination RDC 1180-1 can, for example,use hands-free barcode scanners to scan case label barcodes on casesmoving by them on the CDC sort conveyor (42). A CDC Sort Program (328)of the ePD Delivery Application can read the Case table 1208 to find,for example, a RDC Id, a Local Market Id, a CDC Id, a SKU, and an ePDRetailer Id of the scanned Case Id. The CDC Sort Program (328) canvalidate the RDC Id value in a similar manner as the Local Market SortProgram (326). Although it is highly unlikely to find a case for adifferent RDC on the CDC sort conveyor (42), if such a condition isdetected by the CDC Sort Program (328), the worker performing the CDCsort can react with the same actions as described for the worker thatperformed the local market sort 1118 when a similar error was detected.

After validating the RDC Id, the CDC Sort Program (328) can validatethat the Local Market Id on the Case record 1208 of the scanned casematches the Local Market Id of the current CDC sort conveyor (42). TheLocal Market Id is normally correct for all cases on the CDC sortconveyor (42), but if a picking error was made and the Case record 1208did not have a Local Market Id or had a Local Market Id different thanthe one of the current CDC sort conveyor (42), the CDC Sort Program(328) can correct the situation by updating the Local Market Id to thevalue of the current CDC sort conveyor (42). If the CDC Sort Program(328) does make an update to the Local Market Id on a Case record 1208,the Local Market Case Inventory 1222 data view can be automaticallyupdated in the same manner as it would if the Local Market Sort Program(326) was making the update. This corrective function of the CDC SortProgram (328) can correct the previously described local market sortpicking error in which the Local Market Sort Program (326) processes ascanned case as a reverse local market sort pick instead of a correctivelocal market sort pick.

Consistent with the invention, after checking that the Local Market Idmatches the one for the current CDC sort conveyor (42), the CDC SortProgram (328) can check the CDC Id value. If the program (328) findsthat the Case record 1208 of the scanned case has no CDC Id, it canprocess the scanned case as a CDC sort pick—picking a case from thecurrent CDC sort conveyor (42) to the current CDC packing stationconveyor (44). If it finds that the Case record 1208 has the CDC Id ofthe current CDC packing station conveyor (44), it can process the caseas a reverse CDC sort pick—removing a case from the current CDC packingstation conveyor (44) to the current CDC sort conveyor (42). If theprogram (328) finds a CDC Id of a different CDC packing station conveyor(44), it can process the case as a corrective CDC sort pick—removing acase from its previous CDC packing station conveyor (44) and picking itfor the current CDC packing station conveyor (44).

In processing a CDC sort pick, the program (328) can search for therecord on the CDC Order List data view 1224 with, for example, the SKUand ePD Retailer Id of the scanned case, and the CDC Id associated withthe current CDC packing station conveyor (44). If a record 1224corresponding to that SKU, ePD Retailer Id, and CDC Id combination islocated, the CDC Sort Program (328) can compare the Quantity of thatrecord 1224 against the Quantity of its related record on the CDC CaseInventory data view 1226, if there is one. (A related record can havethe same SKU, ePD Retailer Id, and CDC Id). The CDC Sort Program (328)can subtract the CDC Case Inventory Quantity (representing the totalquantity of an ePD Retailer Id-SKU combination which has already beenpicked for that CDC 1190-1 or LDDH 1192-1) from the CDC Order ListQuantity (representing the total quantity of an ePD Retailer Id-SKUcombination needed to fill the open orders for that CDC 1190-1 or LDDH1192-1) to determine the net quantity of that ePD Retailer Id-SKUcombination still needed for that CDC 1190-1 or LDDH 1192-1. If the CDCOrder List record 1224 does not have a related CDC Case Inventory record1226, the full quantity of the CDC Order List record 1224 can beconsidered the net quantity needed. If the net quantity needed of thatePD Retailer Id-SKU combination for that CDC 1190-1 or LDDH 1192-1 isgreater than zero, the CDC Sort Program (328) can indicate that the caseshould be picked by, for example, producing a pick confirmation tone andcan assign the case to the CDC 1190-1 or LDDH 1192-1 by writing the CDCId of the current CDC packing station conveyor (44) into the CDC Idfield of the Case record 1208 and updating the Status of the Case recordto a value such as “package sort”. Upon hearing the pick confirmationtone (or recognizing another indicator to pick a case), the worker whoscanned the case can pick it from the CDC sort conveyor (42) and placeit on the CDC packing station conveyor (44) of the CDC 1190-1 or LDDH1192-1 for which the worker is working. If there is not a CDC Order Listrecord 1224 for the current CDC 1190-1 or LDDH 1192-1 with the ePDRetailer Id-SKU combination of the scanned case, or if there is one, butthe CDC Sort Program (328) determines that the net quantity needed forit is less than one, the program (328) can indicate that the case shouldnot be picked by, for example, sounding an invalid pick warning tone.Upon hearing the invalid pick warning tone (or recognizing anotherindicator not to pick a case), the worker can let the case pass by onthe CDC sort conveyor (42).

Some cases picked from the CDC sort conveyor (42) onto the CDC packingstation conveyor (44) for a CDC 1190-1 or LDDH 1192-1 can be usedcompletely to satisfy orders for that local market. If that is thesituation, the quantity of the picked case will be less than the netquantity needed for that CDC 1190-1 or LDDH 1192-1. As the net quantityof an ePD Retailer Id-SKU combination needed for a CDC 1190-1 or LDDH1192-1 decreases close to zero, a picked case can have a quantitygreater than the net quantity needed. In that situation, the case can bepicked and the net quantity needed can become negative. After all theitem quantities of that ePD Retailer Id-SKU combination needed to fillorders for the current CDC 1190-1 or LDDH 1192-1 are picked from thatcase to create packages, a CDC sort return marker can be placed on topof the case and the case can be returned to the CDC packing stationconveyor (44). As the worker picking cases from the CDC sort conveyor(42) sees a case traveling around the CDC packing station conveyor (44)with a CDC sort return marker on it, the worker can, for example, pickthe case from the conveyor (44), scan the case's label, place the caseon the CDC sort conveyor (42), flip the CDC sort return markerup-side-down, and place the marker back on the CDC packing stationconveyor (44). Because the CDC Sort Program (328) can determine that theCase record 1208 of the scanned case already has the CDC Id of thecurrent CDC packing station conveyor (44), it can perform reverse CDCsort pick processing. The program (328) can first check to make surethat the needed quantity of the ePD Retailer Id-SKU combination of thescanned case for the current CDC 1190-1 or LDDH 1192-1 is less than one.If the needed quantity is one or greater, the program (328) can sound,for example, an invalid pick tone and can refrain from updating the Caserecord 1208. The worker can, for example, remove the CDC sort returnmarker, place it up-side-down on the CDC packing station conveyor (44),and let the case remain on the CDC packing station conveyor (44). If theCDC Sort Program (328) determines that the needed quantity is less thanone, it can, for example, delete the CDC Id value on the Case record1208 of the scanned case, update the Status of that Case record 1208 toa value such as “CDC sort”, and indicate to pick the case by sounding apick confirmation tone. Upon hearing the pick confirmation tone (orrecognizing another indicator to pick a case) the worker can, forexample, pick the case from the CDC packing station conveyor (44) andplace it on the CDC sort conveyor (42). Changing the Status and removingthe CDC Id value from the Case record 1208 can automatically reduce theQuantity of the ePD Retailer Id-SKU combination of the scanned case onthe CDC Case Inventory data view record 1226, since that Case record1208 will no longer be selected by the CDC Case Inventory data view1226. By reducing the Quantity on the CDC Case Inventory data viewrecord 1226, the net quantity needed for the current CDC 1190-1 or LDDH1192-1 can be increased, since the value that the CDC Sort Program (328)subtracts from the CDC Order List data view record 1224 has beenreduced. If the full needed amount of items was picked from the casebefore the reverse CDC sort pick was done, the reverse pick action canresult in a negative needed quantity being increased to zero.

Situations can occur in which a case is physically on a CDC sortconveyor (42), but logically associated with a CDC packing stationconveyor (44). In one situation, a case can be picked from a CDC packingstation conveyor (44) and placed back on to a CDC sort conveyor (42)without being scanned to initiate a reverse CDC sort pick. In another, acase can be scanned on the CDC sort conveyor (42), but not physicallypicked from that conveyor (42) to a CDC packing station conveyor (44).If a case having a CDC Id because of either situation is travelingaround on the CDC sort conveyor (42) and gets scanned, the CDC SortProgram (328) can process that case as a corrective CDC sort pick. TheCDC Sort Program (328) can update the CDC Id value on the Case record1208 of the scanned case to the value of the current CDC packing stationconveyor (44) and can indicate that the scanned case should be picked,for example, by sounding a pick confirmation tone. The worker can pickthe case from the CDC sort conveyor (42) and place it on the CDC packingstation conveyor (44). In updating the CDC Id on the Case record 1208 ofthe scanned case as part of the corrective CDC sort pick, the CDC SortProgram (328) can correct the error that existed in the CDC CaseInventory data view 1226 by reducing the Quantity of that ePD RetailerId-SKU combination for the CDC 1190-1 or LDDH 1192-1 that it was beingcredited to incorrectly. The corrective CDC sort pick action can alsocorrectly update the CDC Case Inventory data view 1226 for the CDC1190-1 or LDDH 1192-1 of the current CDC packing station conveyor (44)as the scanned case gets picked and placed on that conveyor (44).

An exception to the normal result of a corrective CDC sort pick canoccur when the Case record 1208 of a case on the CDC sort conveyor (42)already has a Status such as “package sort” and a CDC Id, and the workerscanning the case happens to be working at the CDC packing stationconveyor (44) identified by the CDC Id of that Case record 1208. In thissituation, the CDC Sort Program (328) can process the scanned case, forexample, as a reverse CDC sort pick instead of a corrective CDC sortpick. The program (328) can remove the CDC Id from the Case record 1208and make an indication to pick the case, such as sounding a pickconfirmation tone as the worker picks the case from the CDC sortconveyor (42) to the CDC packing station conveyor (44). The result ofthis action actually switches the database from being in error in onedirection to being in error in the opposite direction. Before the casewas scanned and picked, the database incorrectly included the quantityof the case in the CDC Case Inventory data view 1226, when the case wasnot physically on the CDC packing station conveyor (44) of that CDC1190-1 or LDDH 1192-1. After the case gets scanned and picked, the casecan be physically on the CDC packing station conveyor (44), but thedatabase no longer includes the quantity of that case in the CDC CaseInventory data view 1226. This error can be corrected when the case isscanned in the process utilized for creating packages. The CDC sort step1120 can result in cases containing the item quantities needed to fill aCDC's 1190-1 or a LDDH's 1192-1 orders being on the CDC packing stationconveyor (44) of that CDC 1190-1 or LDDH 1192-1.

Once the CDC sort step 1120 is completed, packages can be created fromthe sorted items as illustrated in step 1122. One of the main purposesthat each shipper's RDC can serve within the ePD Delivery Process can beas an origination RDC—acting as an initial receiving point for all casesof product from nearby retailers and sorting and forwarding those casesonto their destination RDC's. Another main purpose a shipper's RDC canserve can be as a destination RDC—creating bulk delivered packages forrecipients from the cases of ordered items received from other RDC's ordirectly from retailers and shipping those packages in bulk to the CDC'sand LDDH's in the local markets served by that RDC.

In accordance with a further aspect of the invention, refrigerateditems, frozen items, and standard temperature items are not packagedtogether, because each type of item requires a different storagetemperature. In the one embodiment, refrigerated and/or frozentemperature items can be packed into packages by retailers at theirfulfillment sites and delivered directly into CDC's 1190-1 by a shipperor the retailer. Because many retailers will either ship only itemsrequiring cold temperature storage or items which can be stored atstandard temperatures, many retailers can employ one order fulfillmentmethod and can either ship item cases to the nearest origination RDC1170 or ship customer packages directly to their destination CDC 1190-1.If a retailer ships both types of items, it can employ separate orderfulfillment methods to ship each type of item. Although in thisexemplary embodiment packages are described as being created in adestination RDC 1180-1 for standard temperature items only, the databaseand programs of the ePD Delivery Application can be designed to providethe capability to create separate packages for items requiring differentstorage temperatures. Retailers that ship bulk delivered packagesdirectly to CDC's 1190-1 can utilize a Retailer Package Creation Program(315) of the ePD Shipping Application or a modified version of their ownorder fulfillment software to create Package records 1234 and printpacking lists and package labels as they create packages to shipdirectly to CDC's 1190-1.

The workers at the destination RDC 1180-1 that create packages can bestationed at a CDC packing station (45) at which they can be working.CDC packing stations (45) designated to a particular CDC 1190-1 or LDDH1192-1 can be located adjacent to the CDC packing station conveyor (44)designated to that CDC 1190-1 or LDDH 1192-1. One RDC worker can beassigned to one CDC packing station (45) at one time, and that workercan be dedicated to the task of creating packages for only the one CDC1190-1 or LDDH 1192-1 to which that CDC packing station (45) isdedicated. A Package Creation Program (330) of the ePD DeliveryApplication can drive the package creation process. CDC packing stations(45) can be grouped together by the CDC 1190-1 or LDDH 1192-1 to whichthey can be dedicated. Each CDC packing station (45) within the groupcan be connected to and can be powered by its own workstation, located,for example, within its back console. Each packing station workstation(not shown separate from a CDC packing station (45)) can run a differentinstance of the Package Creation Program (330), but each instancerunning within the group (of CDC packing stations (45) organized for aspecific CDC 1190-1 or LDDH 1192-1) can have the same pre-definedprogram value for CDC Id. All program instances running within thecurrent destination RDC 1180-1 can have the same pre-defined programvalue for RDC Id and ePD Shipper Id.

There is shown in FIG. 4, an illustrative embodiment of an exemplarypackage creation side of a Customer Distribution Center (CDC) PackingStation. The Customer Distribution Center (CDC) Packing Station of FIG.4, can have the following entities: rack frame (70), large package bagholder (71), small package bag holder (72), fixed location bar codelabel plate (74), packing material storage bin (76), packing documentprinter (77), back console (78), program display monitor (79), keypad(80), label printer (81), package bag storage dispenser (82), andpackage bag storage dispenser opening (83).

Referring to FIG. 4, in one embodiment of the invention, the packagecreating side of a CDC packing station (45) can consist of a rack frame(70) made of metal or a suitable composite which can contain, forexample, multiple wire mesh package bag holders arranged in rows. Forillustrative purposes, there can be 11 package bag holders arranged intotwo rows. Likewise, there can be two different sizes of package bagholders. A CDC packing station (45) can have, for example, large packagebag holders (71) in three of its corners. For example, five of its eightsmall package bag holders (72) can be spaced a few inches apart betweenthe two large package bag holders (71) in the second row of the packingstation. The other three small package bag holders (72) can be in thefront row of the packing station—one can be directly in front of themiddle small package bag holder (72) of the second row and two can bespaced a few inches apart, directly in front of one of the large packagebag holders (71) in the second row of the packing station. There can besufficient space inside the front row of the packing station to allowfree access to the surrounding package bag holders or any of thecomponents on the back console of the packing station (78). The packagebag holders can be spaced a few inches apart from each other on eachside and there can be a few inches of space between the front and secondrows. The tops of the package bag holders in the second row can beraised a few inches above the tops of the package bag holders in thefirst row. The wire mesh package bag holders can be open at the top,having four sides and a bottom. Each package bag holder can have a fixedlocation barcode label plate (74) mounted just above its top edge eithera few inches in front of the center of its top front edge (for thepackage bag holders in the front row) or a few inches behind the centerof its top back edge (for the package bag holders in the second row). Afixed location barcode label plate (74) can be a thin metal or plasticplate with a barcode label affixed to it, and can be attached to thebottom of a package bag holder (71 or 72), for example, by two thinmetal beams which can extend out one or more inches from the front orback side of the package bag holder and can run parallel to the front orback side of the package bag holder. A fixed location barcode labelplate (74) can be designed to allow for a barcode label to be physicallyassociated with a package bag holder, without being covered and/orblocked by a package bag, which can be placed in and around that packagebag holder. A packing station (45) can also have, for example, twopacking material storage bins (76) on either side of the back console(78) extending from and attached to the back of the rack frame of thepacking station (70). These two bins (76) can be made of material, suchas, wire mesh or comparable material similar to the package bag holders.The packing material storage bins (76) can be used to store bubble wrappacking sheets which can be packed between items within a package bag toprotect those items from damage. The back console (78) of the CDCpacking station (45) can be situated behind the rack frame (70) of theCDC packing station (45) in between the two storage bins (76). The backconsole (78) can have, for example, a program display monitor (79), akeypad (80), a packing document printer (77), and a label printer (81).There can be two package bag storage dispensers (82) located on eitherside of the back console (78) at approximately the same height as theprogram display monitor (79). Each of the package bag storage dispensers(82) can have an open back to facilitate loading and an opening (83) inthe center of its front side, through which a worker can take packagebags as they can be needed. One of the package bag storage dispensers(82) can be used to dispense small package bags while the other can beused to dispense large package bags.

In a further embodiment, specially designed ePD package bags can be usedin creating packages. ePD package bags can be made of material, forexample, plastic bubble wrap, which can be approximately one inch inthickness. Pre-sized plastic bubble wrap bags can advantageously cushionand protect items from damage while in transit or in a Smart Bin Unit(SBU) at a CDC 1190-1. Furthermore, pre-sized bags can ensure a properfit for the SBU bins at a CDC 1190-1 when delivered. For illustration,the outer dimensions of the small package bags can measure 12 inches by17 inches by 40 inches, with an inner capacity of 10 inches by 15 inchesby 24 inches. The opening of the small package bag can be approximately10 inches by 15 inches with the thickness of the sides of the bubblewrap bag accounting for the other approximate two inches of each outerdimension. The small package bag can have a pre-marked capacity fillline on it located at approximately 25 inches from the bottom of thebag. As an illustration, the height of the bag can consist ofapproximately 24 inches of inner capacity on top of one inch of thebottom of the bag's thickness, with approximately 15 inches of heightallowing for the bag to be cinched closed at the top—8½ inches (one-halfof 17 inches, the larger of the bag opening's dimensions) to bring thewidest sides of the bag together, plus another 6½ inches (approximatelya handful) of extra material above the point where the bag is cinched.The outer dimensions of the large bags can measure 28 inches by 17inches by 63 inches, with an inner capacity of 26 inches by 15 inches by44 inches. The inner capacity dimensions can be calculated in the samemanner as for the small bag, but the large bag can have three pre-markedcapacity fill lines on it—at 21, 33, and 45 inches. In an alternateembodiment of the invention, other material suitable for packing can beutilized. This can include cardboard boxes, packaging paper, or othermaterial known in the art.

The package bag holders can be sized to fit the package bags inside themallowing for the outer sides of the package bag to fit easily but snuglywithin its mesh wire sides—for illustration, small package bag holders(72) can be approximately 12 inches left to right, by 17 inches front toback, by 25 inches top to bottom; the large package bag holders (71) canbe approximately 28 inches left to right, by 17 inches front to back, by45 inches top to bottom. The extra material of the bubble wrap packagebags extending above the package bag holders (71 & 72) can be foldedback over the top edges and down the sides of the package bag holders.

In one embodiment, each item SKU shippable by the ePD Delivery Processcan be categorized into one of five different sizes. A small-sized SKUcan be one that is small enough to fit into a small package bag. Amedium-sized SKU can be one that is too large to fit into a smallpackage bag, but is small enough to fit into a large package bag. Alarge-sized SKU can be one that is too large to fit into a large packagebag, but is small enough to fit into one of the divided sections withina configured stationary bin of a Smart Bin Unit (SBU) at a CDC 1190-1.An extra-large-sized SKU can be one that is too large to fit into adivided section of a SBU stationary bin, but is small enough to fit intothe largest, undivided, configured stationary bin of a SBU. A LDDH-sizeditem SKU can be too large to fit into the largest, undivided, configuredstationary bin of a SBU and can be considered unshippable to a CDC1190-1, but it can be delivered to a customer-specified address afterbeing distributed to a local delivery distribution hub (LDDH) 1192-1. Inaddition to being too large to fit into SBU bins at a CDC 1190-1,LDDH-sized items can be generally too bulky and heavy for a person tocarry without moving equipment and can therefore be delivered moreefficiently via a LDDH to a customer-specified address. Some SKU's whichcan be small enough to fit into the largest configured stationary bin ofa SBU can still be classified as LDDH-sized if their weight anddimensions make it dangerous or impractical for a recipient to carrythem away from a CDC 1190-1 without moving equipment. Large-sized,extra-large-sized, and LDDH-sized SKU's will be referred to collectivelyas over-sized items throughout the remainder of this disclosure. SKUsize can be tracked on the Case 1208 and Order Detail 1202 tables andsome of the data views created from those tables.

With reference to FIG. 9C, there can be three data views created andused by the Package Creation Program (330) of the ePD DeliveryApplication. One can be a Customer By SKU Order List data view 1228,which can subtotal the Quantity needed for each recipient of each ePDRetailer Id-SKU combination. It can be created from the underlying OrderHeader 1200 and Order Detail 1202 tables by selecting, grouping, andsubtotaling, for example, Customer Id's (representing the recipient ofeach order) and their Quantities for each CDC Id-ePD Retailer Id-SKUcombination. A temperature Code and SKU Size associated with each SKUcan also be selected as part of the data view 1228. The followingillustrative Structured Query Language (SQL) can be used in creating theCustomer By SKU Order List data view 1228:

-   -    select CDC Id, ePD Retailer Id, SKU, Customer Id, Temperature        Code, SKU Size, Quantity from Order Header and Order Detail        where Order Detail.Status=“destination RDC” group by CDC Id, ePD        Retailer Id, SKU, Customer Id, Temperature Code, SKU Size order        by CDC Id, ePD Retailer Id, SKU, Customer Id        A SKU By Customer Order List 1230 can be another data view,        which can be created from the underlying Order Header 1200 and        Order Detail 1202 tables. Instead of selecting Customer Id's and        their Quantities for CDC Id-ePD Retailer Id-SKU combinations,        the SKU By Customer Order List data view 1230 can be created by        selecting and grouping, for example, ePD Retailer Id-SKU        combinations and their Quantities for each CDC Id-Customer        Id-Temperature Code combination. The SKU Size associated with        each SKU can also be selected as part of the data view 1230. The        purpose of this data view 1230 can be to subtotal the Quantity        of each ePD Retailer Id-SKU combination needed for each CDC        Id-Customer Id-Temperature Code combination. The following        illustrative Structured Query Language (SQL) can used in        creating the SKU By Customer Order List data view 1230:    -    select CDC Id, Customer Id, Temperature Code, ePD Retailer Id,        SKU, SKU Size, Quantity from Order Header and Order Detail where        Order Detail.Status=“destination RDC” group by CDC Id, Customer        Id, Temperature Code, ePD Retailer Id, SKU, SKU Size order by        CDC Id, Customer Id, Temperature Code, ePD Retailer Id, SKU        The other data view used by the Package Creation Program (330)        can be an Open Package List data view 1232. It can be created by        selecting, for example, the CDC Id, Customer Id, Temperature        Code, Package Id, Package Bag Holder Id, and Package Size for        each Packing Employee Id from the underlying Package table 1234.        The purpose of this data view 1232 can be to organize selected        package information for the open packages of each worker        creating packages. The following illustrative Structured Query        Language (SQL) can be used in creating the Open Package List        data view 1232:    -    select CDC Id, Packing Employee Id, Customer Id, Temperature        Code, Package Id, Package Bag Holder Id, Package Size from        Package where Status “open” order by CDC Id, Packing Employee        Id, Customer Id, Temperature Code        All three data views can be dynamically updated as data changes        on their underlying tables. The ePD Retailer Id's and SKU's can        be selected together in combination for the data views to ensure        that a customer who orders a particular SKU from one retailer        does not receive the same SKU from a different retailer who may        sell the same item. Customer Id's and Temperature Codes can be        selected together in combinations to separate items, requiring        different shipping and storage due to their temperature, into        different packages, even if those packages are for the same        recipient and CDC 1190-1 or LDDH 1192-1.

The Package Creation Program (330) can use the three data views incombination with its program rules to coordinate the creation ofpackages by multiple workers destined for recipients at one CDC 1190-1or LDDH 1192-1. The Package Creation Program (330) can allow one openpackage at a time for a given combination of recipient, temperaturecode, and CDC 1190-1 or LDDH 1192-1. It is possible for a recipient tohave more than one open package if the packages are for different CDC's1190-1 or LDDH's 1192-1 or if the packages have different temperaturecodes. As one worker closes or completes a package for a given CustomerId-Temperature Code-CDC Id combination, a new package can be opened forthat same combination by that same worker or by another worker. ThePackage Creation Program (330) can attempt to pick a SKU to finish anopen package, before it picks a SKU to create a new package. Each workercan have a limited number of small-sized and medium-sized packages openat one time, which can be configured based upon the number of packagebag holders of each size contained within their packing station (45). Inone embodiment a worker may have up to three medium-sized and eightsmall-sized packages open at the same time. When creating a new packagefor a recipient, the Package Creation Program (330) can determine thesize of the package by the size of the SKU's needed for that recipient(Customer Id). If the SKU Size on any of the SKU by Customer Order Listrecords 1230 for the open orders of a Customer Id-Temperature Codecombination for the current CDC Id is a value such as “medium”, thePackage Creation Program (330) can direct the worker to use one of thelarge package bag holders on the packing station (45). If all of the SKUSizes needed for the open orders of a Customer Id-Temperature Codecombination for the current CDC Id are either small-sized or over-sized,the Package Creation Program (330) can direct the worker to use one ofthe small package bag holders when the case of one of those small-sizedSKU's is scanned. Over-sized items are not packed into package bags withother items. The Package Creation Program (330) can treat them asseparate single-item packages and can direct workers to apply packagelabels directly to them. In one aspect of the invention, when a caselabel is scanned by a worker at a packing station (45), the PackageCreation Program (330) can result in one of several actions, which caninclude but are not limited to: a prompt to pick a specified quantityfrom the scanned case to pack into one of the worker's existingpackages; a prompt to create a new package with a specified quantityfrom the scanned case; a prompt to label the case as a large single-itempackage; or an indication to let the scanned case pass by on the CDCpacking station conveyor (44).

Each packing station (45) can be divided into several parts. Forexample, there can be two main parts, namely, a package creation side asillustrated in FIG. 4 and a package sealing side (FIG. 5). There isshown in FIG. 5, an illustrative embodiment of an exemplary PackageSealing side of a Customer Distribution Center (CDC) Packing Station.The Package Sealing side of a Customer Distribution Center (CDC) PackingStation can have the following entities: pick confirmation light (84),scanner port (86), trimming slot (88), package tie holder (90), tieholder lock button (92), package sealer compartment (94), package guidering (96), package holding ring (98), tie holder release button (100),package holder lock button (101), package holder release button (102),package holder support base (103), package sealing station top (104),packing list pouch storage bin (105), and package tie storage bin (106).

Referring to FIG. 5, the package sealing side can be built onto the edgeof a CDC packing station conveyor (44). The package creation side (FIG.4) can be an independently standing structure, which can be locatedopposite to the package sealing side, with working space in between thetwo sides in which a worker is able to move. A RDC worker can log intoan instance of the Package Creation Program (330) by using, for example,a hands-free barcode scanner attached to a CDC packing station (45) toscan their employee identification (id) card. The hands-free scanner canbe plugged into a scanner port (86) on the package sealing side of theCDC packing station (45) at which the worker is stationed. Upon logginginto the program (330), the scanned employee id value can be written tothe Packing Employee Id field of all the records on a Package Bag Holdertable 1236 associated with that worker's packing station (45). As a casemoves by on the current CDC packing station conveyor (44) the worker canscan the barcode on the case label. The Package Creation Program (330)can read the Case Id from the scanned barcode and use it to retrieveinformation such as, the ePD Retailer Id and SKU of that case from theCase table 1208. The Package Creation Program (330) can use the ePDRetailer Id, SKU, and the CDC Id associated with the current CDC packingstation (45) to retrieve data records from the Customer By SKU OrderList data view 1228. The retrieved records can be a listing of all therecipients for whom an ordered item of the scanned case is to bedelivered to the current CDC 1190-1 or LDDH 1192-1. Each of theretrieved data records 1228 can include information such as the CustomerId, Temperature Code, SKU Size, and Quantity of the item ordered by thecustomer. The program can check the SKU Size of the first Customer BySKU Order List record 1228 retrieved to determine if single-item packageor multi-item package processing should be followed. If the selectedrecord's 1228 SKU Size is a value such as “large”, “extra-large”, or“LDDH”, single-item package processing can be performed. If the selectedrecord's 1228 SKU Size is a value such as “small” or “medium”,multi-item package processing can be performed.

There is shown in FIG. 7, an illustrative embodiment of an exemplarylayout of a Package Creation Screen. The Package Creation Screen canhave the following: Package bag indicator 108, Single item packageindicator 109, Pick quantity indicator field 112, Message field 114,Current case information display section 116, Current packageinformation display section 118, Close out list information displaysection 120, Information display section title 122, Information displaysection column header 124, Information display section line detail 126,Current package information display—package indicator 128, and Packagelist scroll bar 130. One of the package bag indicators 108 can bedisplayed as a highlighted package bag indicator 110, when the PackageCreation Program (330) is trying to identify a package bag as part of aprogram action. As part of a multi-item package processing, the PackageCreation Program (330) can use the current CDC Id (the CDC Id associatedwith the current CDC packing station (45)) and the worker's Employee Idto select records from the Open Package List data view 1232, having thecurrent CDC Id in the CDC Id field and the worker's Employee Id in thePacking Employee Id field. The Package Creation Program (330) can readthe list of Customer Id-Temperature Code combinations from the selectedOpen Package List records 1232 sequentially, searching for each CustomerId-Temperature Code combination in the data that was retrieved from theCustomer By SKU Order List data view 1228 when the case was scanned.Whenever a match is found, the worker can already have an open package,having the same temperature code as the scanned case, for a recipientfor whom the item of the scanned case was ordered. The Package CreationProgram (330) can make an indication to pick one or more items from thecase, for example, by sounding a pick confirmation tone, lighting up thepick confirmation light (84), highlighting the package bag indicator(108) containing that recipient's open package, displaying the quantityto pick in the pick quantity indicator field (112), and displaying amessage in the message field (114) of a Package Creation Screen,illustrated in FIG. 7, on the program display monitor (79).

The displayed message can direct the worker to pack the indicatedquantity of the item in the scanned case into the package bagrepresented by the highlighted package bag indicator (110) and scan thefixed location barcode label plate (74) of the highlighted package bag.The Package Creation Program (330) can determine which package bagindicator (108) to highlight from a Package Bag Holder Id on theselected Open Package List record 1232. A Package Bag Holder Id can be afixed value that represents a particular package bag holder (71 or 72)on a packing station (45) and the package currently in that package bagholder (71 or 72). The Package Creation Program (330) can determine thevalue to display in the pick quantity indicator field (112) by selectingthe Quantity on the underlying Order Detail record 1202 of thetransaction. To select the transaction's underlying Order Detail record1202, the Package Creation Program (330) can search for a record 1202containing the Customer Id, for which it was able to find a matchbetween the Open Package List record 1232 and the Customer By SKU OrderList record 1228, the current CDC Id, and the ePD Retailer Id and SKU ofthe scanned case. If the recipient (represented by Customer Id) has morethan one open order (Order Detail record 1202 having a Status such as“destination RDC”) for the current CDC 1190-1 or LDDH 1192-1 containingthe item of the scanned case, the Order Detail record 1202 associatedwith the Order Header record 1200 having the earliest Order Date/Timecan be selected. Upon hearing the pick confirmation tone or seeing thepick confirmation light (84) flash (or recognizing another indicator topick an item from the scanned case), the worker can pick the case fromthe CDC packing station conveyor (44) and for example, place it on topof the packing station—on either the package sealing side (FIG. 5) orthe package creation side (FIG. 4). The worker can look at the caselabel to determine if the case is a single-item case or a multi-itemcase. If the case label does not have an indicator, such as a large “S”printed on it, to indicate a single-item case, the worker can, forexample, open the case (if it has not already been opened), pick theindicated quantity of items from the case, pack the indicated quantityof items into the highlighted package bag, enter the picked quantityusing for example, the packing station keypad (80), and scan the fixedlocation barcode label plate (74) associated with the highlightedpackage. When packing the items into the package bag, the worker can usepacking materials such as bubble wrap packing sheets, which can bestored in the packing material storage bin (76), as needed to protectthe items from damage.

The Package Creation Program (330) can determine the Package Idassociated with the scanned fixed location barcode label plate (74) bysearching the Package table 1234 for the record having the Package BagHolder Id that is printed in barcode format on that label plate (74) anda Status such as “open”. The program (330) can validate the scannedPackage Bag Holder Id against the Package Bag Holder Id selected fromthe Open Package List data view 1232. If it does not match, the workerscanned a different label plate (74) by mistake and the program (330)can signal that an error has occurred, for example, by sounding an errortone and displaying a message indicating that the wrong package wasscanned. The program (330) can also validate the quantity entered on thekeypad (80) against the value in the Quantity field of the selectedOrder Detail record 1202 underlying the transaction. If the enteredquantity does not match, the worker entered a different value and theprogram (330) can signal that an error has occurred, for example, bysounding an error tone and displaying a message indicating that thewrong quantity was entered. If the worker did not enter a quantitybefore scanning the barcode on the label plate (74), the program (330)can signal that an error has occurred, for example, by sounding an errortone and displaying the same error message as it does when the wrongquantity is entered. Upon successful validation, the Package CreationProgram (330) can update the selected Order Detail record 1202 bysetting its Status to a value such as “package”, writing the Package Idfrom the selected Open Package List record 1232 to the Package Id field,and writing the Case Id of the scanned case to the Case Id field. ThePackage Creation Program (330) can also update the Case record 1208 ofthe scanned case by decrementing its Quantity by the quantity the workerentered on the keypad (80). After the worker enters the indicated pickquantity and scans the correct label plate (74), the program (330) canindicate that the picked quantity of items was successfully associatedwith the package of the scanned label plate (74), for example, bysounding another confirmation tone and displaying a confirmation messageconfirming that the picked items were added to the package successfully.

If a match was not found when the worker scanned the case label and theprogram (330) searched for the Customer Id-Temperature Code combinationsof the worker's open packages on the Customer By SKU Order List records1228 having the current CDC Id and the ePD Retailer Id-SKU combinationof the scanned case, then none of the recipients of the worker's openpackages require an item from the scanned case. The program (330) canthen check to see if a new package should be created for a recipientusing the items of the scanned case. The Package Creation Program (330)can determine whether a new package should be created by sequentiallyreading the records selected from Customer By SKU Order List 1228 forthe current CDC Id and the ePD Retailer Id-SKU combination of thescanned case, checking for the Customer Id-Temperature Code combinationof each record 1228 on the Open Package List records 1232 having thecurrent CDC Id. If all the Customer Id-Temperature Code combinations onthe Customer By SKU Order List 1228 are also on the Open Package List1232, then all the recipients for whom that item has been ordered fordelivery to the current CDC 1190-1 or from the current LDDH 1192-1 canalready have open packages with other workers. In this situation, a newpackage should not be created. The Package Creation Program (330) canindicate not to pick items from the case, for example, by sounding aninvalid pick tone, turning off the highlight of whichever package bagindicator (108) was previously highlighted, setting the pick quantityindicator field (112) to zero, and displaying a message in the messagefield (114) of the Package Creation Screen. The message can direct theworker not to pick items from the scanned case, because its items areintended for packages at other packing stations (45).

If the Package Creation Program (330) was able to find a CustomerId-Temperature Code combination on the Customer By SKU Order List dataview 1228, for which there was not a matching record on the Open PackageList data view 1232, when trying to determine whether a new packageshould be opened for a recipient, then that recipient does not have anopen package at any packing station (45) for the current CDC 1190-1 orLDDH 1192-1 and a new package should be created. To create a newpackage, the program (330) can check to determine if the worker hasavailability at the packing station (45) to start the new package.Determining packing station availability can include determining thepackage size. The Package Creation Program (330) can determine thepackage size needed for the recipient by searching the SKU By CustomerOrder List data view 1230 for all of the records with the current CDC Idand Customer Id-Temperature Code combination. If any of the selectedrecords 1230 has a SKU Size value such as “medium”, the Package CreationProgram (330) can search the Package Bag Holder table 1236 for recordscontaining the worker's id in the Packing Employee Id field, a Statussuch as “available”, and a Package Bag Holder Size such as “large”. Ifnone of the selected records has a SKU Size value such as “medium”, thePackage Creation Program (330) can search the Package Bag Holder table1236 for records containing the worker's id in the Packing Employee Idfield, a Status value such as “available”, and Package Bag Holder Sizevalue such as “small”. If the Package Creation Program (330) doesn'tfind an available package bag holder (71 or 72) of the right size, itcan indicate that a new package cannot be created with items from thescanned case, for example, by sounding an invalid pick tone, turning offthe highlight of whichever package bag indicator (108) was highlighted,setting the pick quantity indicator field (112) to zero, and displayinga message in the message field (114) of the Package Creation Screen. Themessage can direct the worker not to pick items from the case, becausethe worker's packing station (45) doesn't have a package bag holder ofthe correct size (71 or 72) available. It can be possible for a workerto override the Package Creation Program (330) and start a new packagefor the recipient, using for example, a package creation override keysequence on the packing station keypad (80), if the Package CreationProgram (330) was looking for a small package bag holder (72) and only alarge one (71) was available.

On finding an available package bag holder (71 or 72) of the appropriatesize, the Package Creation Program (330) can create a new record on thePackage table 1234 having, for example, the Customer Id and TemperatureCode from the Customer by SKU Order List 1228, the value of the currentCDC Id of the packing station (45), the ePD Shipper Id and RDC Id valuesof the current destination RDC 1180-1, the Packing Employee Id of theworker logged into the current instance of the program (330), thePackage Bag Holder Id from the selected Package Bag Holder record 1236,and a Status set to a value such as “open”. The Package Id value on thenew record can be generated, for example, by concatenating CustomerId+RDC Id+current date+a sequential 3 digit number. All other fields canbe initially created without values. The program can update the selectedPackage Bag Holder record 1236, setting Status to a value such as“package” and Package Id to the value of the newly created Packagerecord 1234. In addition to creating the new Package record 1234 andupdating the selected Package Bag Holder record 1236, the program (330)can indicate to pick items from the scanned case for a new package, forexample, by sounding a confirmation tone, lighting up the pickconfirmation light (84), highlighting the package bag indicator (108) ofthe selected package bag holder where the new package can be created,displaying the quantity to pick in the pick quantity indicator field(112), and printing a package label. Package labels can contain thePackage Id in both a barcode and a readable format and the destinationCDC Id in a readable format. The Package Creation Program (330) can alsodisplay a message in the message field (114) directing the worker tocreate a new package.

The worker can pick the case from the CDC packing station conveyor (44)and place it on top of the packing station (45). The worker can take anew package bag of the appropriate size from one of the package bagstorage dispensers (82) (depending upon whether the program (330)highlighted a large or small bag holder). After peeling the packagelabel from the label stock printout, which can be hanging out of thepacking station's label printer (81), the package label can be affixedto the outer surface of the package bag. Package labels can be placed onthe side of package bags near the bottom. The worker can scan thebarcode on the package label and position the package bag in the packagebag holder (71 or 72) indicated by the highlighted package bag indicator(110), pushing the bottom of the bag down into the center of the packagebag holder (71 or 72), and folding the sides of the package bag, whichcan extend above the top of the package bag holder (71 or 72), downaround the outside edges of the package bag holder (71 or 72). Thepackage bag can be pushed down into the package bag holder (71 or 72) sothat the top fill line marked on the package bag is aligned with the topof the package bag holder (71 or 72). After labeling and positioning thenew package bag in a package bag holder (71 or 72), the remainingactions of creating a new package—picking the indicated quantity ofitems from the scanned case into the new package—can be the same aspicking items into an existing package (as previously described).

The step of scanning the barcode label on the package bag, in creating anew package (between the normal packing steps of scanning a case labeland then scanning a fixed location barcode label (73)), can associatethe package bag label with a specific package bag holder location on thepacking station (45). For the time while a package is open and in theprocess of being packed, the Package Creation Program (330) can considerthe value of the fixed location barcode label (73) to be synonymous withthe value of the barcode on the package label. This can enable thePackage Creation Program (330) to validate that a package has beeninitially set up in the correct package bag holder (71 or 72), and tovalidate on each packing action that the worker has packed the itemsinto the correct package.

After a worker picks a quantity of an item from a case and packs it intoeither a new or an existing package, the picked case can be sitting ontop of the worker's packing station (45). Before returning the case tothe CDC packing station conveyor (44), the worker can scan the barcodelabel on the case again to see if additional items should be picked fromit. The Package Creation Program (330) can perform the processing thatit performs when a case is scanned, which can result in the workerpacking another quantity from that case into an existing package,creating a new package, or placing the case back onto the conveyor (44).The worker can continue to scan the case until the case is empty or theprogram (330) directs the worker to return the case to the conveyor(44). When the program (330) determines that a case is empty—forexample, when the Quantity on the Case record 1208 has been decrementedto zero—it can display a message indicating that the case is empty.Empty cases can be placed back onto the conveyor (44) and can be movedthrough the destination RDC 1180-1 to one of the local market shippingdock conveyors (48) to be sent into a recycling process.

If a case only has part of the quantity needed for a customer order, thePackage Creation Program (330) can indicate a need to pick only theremaining quantity in the case. After the worker scans the barcode onthe fixed location barcode label plate (74) of the package, the PackageCreation Program (330) can update the existing Order Detail record 1202as it normally would when performing a pack action, including writingthe Package Id and Case Id to the record 1202 and changing the Status toa value such as “package”. In addition to its normal updates, thePackage Creation Program (330) can reduce the Quantity on the OrderDetail record 1202 to equal the picked quantity and can create a newOrder Detail record 1202 with the same information as the existingrecord except for a few differences. The differences can be that thePackage Id and Case Id can be empty, Status can be set to a value suchas “destination RDC”, and Quantity can be set to the difference betweenthe Quantity value that was on the existing record before it wasupdated, and the Quantity value to which it was updated. If the PackageCreation Program (330) directs the worker to pick a higher quantity thanwhat is physically in the case, the worker has uncovered a previouslymade packing error—an over-packing error. In this situation, the workercan leave the items in the case, cancel the current pick action, run aRDC Package Inspection Report, and place the case to the side of thepacking station (45). After the program (330) makes the previouslydescribed update to the Status on Order Detail records 1202 as items arepacked into packages (updating Status from a value such as “destinationRDC” to a value such as “package”), it can check the CDC Order List 1224and Local Market Order List 1220 data views to determine if there isstill a demand for the scanned case's items in both the current CDC1190-1 and the current local market. If the (needed) Quantity of the ePDRetailer-SKU combination for the current CDC Id on the CDC Order List1224 reaches zero, as the Quantity on the underlying Order Detail record1202 is decremented, the Package Creation Program (330) can, forexample, sound a message alert tone and display a message on the PackageCreation Screen, indicating that the scanned case should be redirectedback to the CDC sort conveyor (42) of the local market. The worker canplace, for example, a CDC sort return marker on top of the case afterplacing the case back onto the CDC packing station conveyor (44). Uponseeing a case with a CDC sort return marker, a worker performing the CDCsort function 1120 for the current CDC 1190-1 or LDDH 1192-1 can scanthe case to initiate a reverse CDC sort pick and can move the case backto the CDC sort conveyor (42) of the current local market. When movingthe case, the CDC sort worker can, for example, remove the CDC sortreturn marker, flip it up-side-down, and place it back on the CDCpacking station conveyor (44). The CDC sort return marker can have forexample, a packing station id written on one side and text such as “CDCsort” on the other. When the packing worker who originally placed theCDC sort return marker on the case sees the marker on the CDC packingstation conveyor (44) with their packing station id on it, the workercan retrieve it for later use.

When the (needed) Quantity of the ePD Retailer-SKU combination for thecurrent Local Market Id on the Local Market Order List data view 1220reaches zero, the Package Creation Program (330) can, for example, sounda message alert tone and displays a message on the Package CreationScreen, indicating that the scanned case should be redirected back tothe local market sort conveyor (24). The worker can place, for example,a local market sort return marker on top of the case after placing thecase back onto the CDC packing station conveyor (44). Upon seeing a casewith a local market sort return marker, a worker performing the CDC sortfunction 1120 for the current CDC 1190-1 or LDDH 1192-1 can scan thecase to initiate a reverse CDC sort pick and can move the case, with thelocal market sort return marker still on top of it, back to the CDC sortconveyor (42) of the current local market. Upon seeing a case on the CDCsort conveyor (42), with a local market sort return marker, a workerperforming the local market sort function 1118 for the current localmarket can scan the case to initiate a reverse local market sort pickand can move the case back to the local market sort conveyor (24). Whenmoving the case, the local market sort worker can remove the localmarket sort return marker, flip it up-side-down, and place it back onthe CDC sort conveyor (42). The local market sort return marker canhave, for example, a CDC Id and a packing station id written on one sideand text such as “local market sort” on the other. When a CDC sortworker sees the marker with the CDC Id on it, the worker can pick itfrom the CDC sort conveyor (42) and place it on the CDC packing stationconveyor (44) at which the worker is working. When the packing workerwho originally placed the local market sort return marker on the casesees the local market sort return marker on the CDC packing stationconveyor (44), with their packing station id on it, the worker canretrieve it for later use.

The Package Creation Program (330) can also check the SKU By CustomerOrder List data view 1230, after the Order Detail Status update is madeduring the packing action, to determine if there are any remaining OrderDetail records 1202 for that recipient (represented by Customer Id) witha Status value such as “destination RDC” and a SKU Size such as “small”or “medium”. If it finds at least one record on the SKU by CustomerOrder List data view 1230 having the Customer Id of the Order Headerrecord 1200 underlying the SKU by Customer Order List data view record1230, a SKU Size such as “small” or “medium” and a Status such as“destination RDC”, then there are still some items currently in thedestination RDC 1180-1 to be packed for that recipient and the PackageCreation Program (330) can refrain from initiating an action to closethat recipient's package. If the program (330) is unable to find any SKUby Customer data view records 1230 for that recipient having a SKU Sizesuch as “small” or “medium” and a Status such as “destination RDC”, thenthere are no items remaining in the destination RDC 1180-1 for thatrecipient which are small enough to be packed into a package for therecipient and the Package Creation Program (330) can, for example, sounda message alert tone and display a message in the message field (114) ofthe Package Creation Screen, indicating that the package should beclosed.

The worker can also initiate the action to close a package by, forexample, pressing a close package key on the packing station keypad(80), and then confirming the action by pressing a confirmation key,when the Package Creation Program (330) prompts for a confirmation. Theconfirmation prompts of the ePD Delivery Application's programs canconsist of displaying a message which shows the worker what action isbeing confirmed and asks the worker to press a confirmation key. Therecan be several circumstances in which a worker realizes the need toclose a package. One circumstance can occur when the worker has finishedpacking the full quantity of a picked SKU into the package bag and seesthat although the SKU quantity fit in the package bag completely, thereis very little remaining available space below the package's top fillline for other items. Another circumstance can occur when the workerscans a case and the Package Creation Program (330) can direct theworker to pick one or more items into a package bag in which there isnot enough space available to accept the full quantity of items. In thelatter situation, the worker can pack as many of the items into thepackage as can be accommodated and can key in the quantity that waspacked. If the items are too large to pack even one of them into thepackage, the worker can enter a zero for the quantity. When the workerenters a quantity less than what the Package Creation Program (330)directed the worker to pick, the Package Creation Program (330) canindicate that the correct quantity was not picked by, for example,sounding an error tone and displaying a message indicating that thecorrect quantity was not entered and the picked quantity should eitherbe re-entered or confirmed. If there was truly either a picking error ora data entry error, the worker can count the quantity in the package,compare it to the quantity directed by the Package Creation Program(330), and re-pick and/or re-enter the quantity so that the quantitypicked matches both the quantity entered and the quantity directed bythe Package Creation Program (330). If the situation was not really anerror, but one in which the worker needs to open a new package for thepicked items, instead of re-entering the amount picked, the worker canclose the package by, for example, pressing a close package key or othersuitable key. The Package Creation Program (330) can prompt the workerto confirm the action, and when the worker presses the confirmation key,the Package Creation Program (330) can update the Order Detail 1202 andCase 1208 records to reflect the actual amount picked. The update to theOrder Detail record can be made in the same way as the one describedearlier, in which the picked quantity is less than the amount directedby the Package Creation Program (330) because only part of the orderedamount is available in the case—a new Order Detail record 1202 can becreated having the unpicked quantity. If the quantity picked and enteredwas zero, the program (330) can end the pick/pack action and begin theclose package action without making any updates to the Order Detail 1202or Case 1208 records.

Regardless of whether the Package Creation Program (330) or the workerinitiates a close package action, the Package Creation Program (330) andworker can follow the same set of package closing procedures. If thepackage is in one of the large package bag holders (71), the program(330) can display a message on the program display monitor (79) toprompt the worker to enter the package size. The worker can look intothe package bag to count the number of visible fill lines on the insideof the package. The worker can enter the number of visible fill linescompletely above all the items in the package as the package size (“3”,“2”, or “1”). The Package Creation Program (330) can update Status onthe Package table 1234 to a value such as “closed” and can set thePackage Size to a value such as “2”, “3”, or “4” depending upon thevalue entered by the worker—for example, an entered value such as “3”can be set to a Package Size such as “2”, an entered value such as “2”can be set to a Package Size such as “3”, and an entered value such as“1” can be set to a Package Size such as “4”. If the package is in oneof the small bag holders, the program (330) can update Status on thePackage table to a value such as “closed” and can set the Package Sizeto a value such as “1”, without prompting the worker to enter a packagesize.

The Package Creation Program (330) can call or initiate or cause to beinitiated, a Packing List Report Program (332) to print packing listsfor the items in the package. A separate packing list can be created foreach distinct retailer having items in the package. Each packing listcan contain the same basic information—the quantity of each SKU includedin the package—as well as retailer specific information—retailer ordernumber(s), a customizable packing list header message, a customizableorder header message, and customizable line item detail messages. Theretailer order number can be a different number than the Order Id. Apacking list can also contain an Order Id for each order listed on itand an item return barcode for each line item listed on it. An itemreturn barcode can contain, but is not limited to the followinginformation associated with a line item printed in barcode format:Package Id, Order Id, and SKU. Each retailer can provide specificationsand/or document templates to shippers to enable a packing list to beprinted to look exactly the way it would if the retailer had printed ititself. To create the packing lists, the Package Creation Program (330)can select a list of Order Detail records 1202 with the Package Id ofthe current package, sorted by, for example, Order Id. The PackageCreation Program (330) can use the Order Id to select the correspondingOrder Header records 1200 and can then pass certain data fields to thePacking List Report Program (332). These fields can include, but are notlimited to, the ePD Retailer Id, Order Id, Customer Id, ePD Shipper Id,Order Date/Time, Retailer Order Number, Retailer Message-Order Header,Retailer Message-Packing List, SKU, Quantity, Package Id, and RetailerMessage-Order Detail. The Package Creation Program (330) can pass theOrder Header 1200 and Order Detail 1202 data selected for the currentpackage to the Packing List Report Program (332) one retailer at a time,for example, by sub-selecting data from the selected data using each ePDRetailer Id contained in the selected data. If one retailer has morethan one order in the same package, the report information can begrouped by Order Id, with common header information printed at the topof the report and order-specific header information printed at the topof each order grouping. The Package Creation Program (330) can thensub-select the data corresponding to the next retailer, from the dataselected for the current package, and can call or cause to be called thePacking List Report Program (332) again to print the next packing listfor the current package. This sub-process can be repeated until allpacking lists are printed for the current package. The worker can takethe packing list reports from the packing document printer (77) andplace them inside the package bag.

After putting packing lists in the package, the worker can seal thepackage, for example, by pulling up the sides of the package bag fromaround the outside of the package bag holder (71 or 72) and cinchingthem closed above the packed items. The package bag can then be liftedout of the package bag holder (71 or 72) and brought to the packagesealing side of the packing station (FIG. 5). The following descriptionof sealing a package bag using the exemplary package sealing side of aCDC packing station depicted in FIG. 5 is an illustrative example of howa package can be sealed after it is created at a destination RDC 1180-1,other suitable means and methods can alternately be used to close apackage bag in the create packages step 1122 of the ePD DeliveryProcess. The package can be placed in the package sealer compartment(94) by sliding the cinched part of the package bag through the trimmingslot (88), while placing the bulk of the package containing the itemsbelow the package sealing station top (104). When placing the packagebag into the package sealing side of the packing station (FIG. 5), theworker can hold the cinched part of the package bag with two hands, onetightly holding the bag closed just above the items, and the otherseveral inches above the lower hand. In the motion to slide the cinchedpart of the package bag through the trimming slot (88), the worker canpush the bottom portion of the cinched part of the package bag, belowtheir lower hand, into the package guide ring (96), and the top portionof the cinched part of the package bag, between their upper and lowerhands, into the package holding ring (98). In entering the package guidering (96), the package bag can push the spring-hinged collapsible sideof the package guide ring (96) to force entry inside the ring, and thespring-hinged collapsible side of the package guide ring (96) can springback into its normal position, reforming a solid ring around the cinchedpart of the package bag. The package holding ring (98) can have a gap inits outer edge, which can allow the worker to pass the cinched part ofthe package bag through its outer edge to its inner circumference. Atthis point, the package bag can be suspended above the bottom of thepackage sealer compartment (94) by the worker's hands, although thepackage guide ring can now be holding the top of the bag cinchedtogether. The worker can release one of their hands from holding thepackage bag and use it to press the package holder lock button (101).When the package holder lock button (101) is pressed, the inside of thepackage holder ring (98) can constrict around the top portion of thecinched part of the package bag, until it is tight enough to hold theweight of the package. The worker no longer needs to hold the package asit can be suspended within the package sealer compartment (94) by thepackage holder ring (98). The package holder ring (98) can be attachedto and supported by a package holder support base (103). The packageholder support base (103) can be attached to and supported by the entirestructure of package sealing side of the packing station (FIG. 5), whichcan be attached to and supported by the CDC packing station conveyor(44) and the floor of the destination RDC facility 1180-1.

For illustration, the package ties used to seal packages can be a strandof tubular rubber approximately 30 inches long and 3/16^(th) of an inchin diameter. Once the package is held in place by the package sealingside of the packing station (FIG. 5), the worker can grab a package tiefrom the package tie storage bin (106) and pull the two ends of thepackage tie together. The worker can place the two ends in the packagetie holder (90) and press the tie holder lock button (92) to secure thepackage tie in place. The package tie holder (90) can clamp down on thetwo ends of the package tie to hold them in place securely. The workercan grab the package tie and stretch it to find its mid-point. Holdingit at its mid-point, the worker can loop the double-strands of thepackage tie around the bottom of the cinched part of the package bag,just above the package guide ring (96), and pull it through the loop toform a knot. The worker can continue to pull the mid-point of thepackage tie toward them, tightening the knot around the cinched part ofthe package bag. A package handle can be formed by the loop of excesspackage tie on one side of the knot, which can now be sealing thepackage closed. The worker can press the package holder release button(102) initiating movements by the components that make up the packageholder ring (98). Cutting blades which can be located on the undersideof the package holder ring (98), can move toward the center of the ringto cut through the cinched package bag material in one movement. Inanother movement the package holder cutting blades can move back totheir original state within the protective cutting blade covers on theunderside of the package holder ring (98). In another movement theinside edges of the package holder ring (98), which are constricting thepackage bag material that has now been separated from the package, canmove back to their original non-constricted position. Package labelsthat were applied near the bottom of package bags can remain on thepackage undamaged, when the excess material at the top of the package istrimmed away. After the excess material at the top of the package hasbeen severed, the package is no longer suspended by the package holderring (98), but the weight of the package can now be supported by thepackage tie knot and the two ends of the package tie, which can beclamped to the package sealing station top (104) by the package tieholder (90). The worker can grab the scraps of package bag material thathave been cut away from the top of the package and place them in a scrapcontainer. The worker can slip one of their hands through the packagetie handle and can press the tie holder release button (100) with theirother hand. The package tie holder (90) can be lifted off of the twoends of the package tie and the worker can now be holding the package upby its package tie handle. The worker can grab the bottom of the packagewith their other hand and lower it to the bottom of the package sealercompartment (94), removing their hand from the package tie handle andletting the cinched part of the package and the package tie handle toslip down through the package guide ring (96) and the trimming slot(88). The package tie handle can then be used to lift the package out ofthe package sealer compartment (94), and it can be placed on the CDCpacking station conveyor (44). After sealing the package and placing iton the conveyor (44), the worker can return to the case at their packingstation (the case from which the worker had last picked the items forthe package that the worker has just finished sealing). The worker canscan the case to have the program (330) direct their next action.

In another aspect of the invention, single-item package processing canbe performed when cases containing one over-sized item (large-sized,extra-large-sized or LDDH-sized) are scanned by a worker creatingpackages at a CDC packing station (45). Although all items received intoa destination RDC 1180-1 have been referred to as being in cases, itshould be readily understood by one skilled in the art that anover-sized item case may actually just be a single over-sized item witha case label attached to it rather than an over-sized item physicallyinside a box or other suitable container. Some over-sized items may betoo large or odd shaped to fit into a box or other suitable container.When a worker scans the case label of an over-sized item case, thePackage Creation Program (330) can read the Case Id and perform the sameinitial actions as it does when processing a case containing asmall-sized or medium-sized SKU. It can retrieve a listing of recordsfrom the Customer By SKU Order List data view 1228 and can check the SKUSize of the first record 1228 to determine whether single-item packageprocessing or multi-item package processing should be performed. Theretrieved record can represent a list of all the recipients for whichthe item of the scanned case has been ordered for delivery to/from thecurrent CDC 1190-1 or LDDH 1192-1. Because an over-sized item has beenscanned, the program (330) can find an over-sized SKU Size on theselected Customer by SKU Order List data view 1228 and can performsingle-item package processing. Instead of selecting a list of recordsfrom the Open Package List data view 1232 to try to determine if thecurrent packing employee has any open packages, for any of therecipients on the selected Customer by SKU Order List records 1228, insingle-item package processing, the program (330) can simply create asingle-item package to meet the demand of the first selected Customer bySKU Order List record 1228. To ensure that two workers picking the sameitem SKU at approximately the same time do not fill the same order, theprogram (330) can, for example, select and invoke a table-lock on theunderlying Order Detail record 1202 before updating it. If anotherinstance of the program (330) has already table-locked or updated theOrder Detail record 1202 underlying the first record selected from theCustomer by SKU Order List data view 1228, before the current instanceis able to invoke a table-lock on it, the current instance of theprogram (330) can attempt to select and invoke a table-lock on the OrderDetail record 1202 underlying the next record selected from the Customerby SKU Order List data view 1228. Other methods of preventing multiplesimultaneous modifications to records of a database are well known inthe art. The Package Creation Program (330) can update the Order Detailrecord 1202 in single-item package processing in the same manner as itdoes in multi-item package processing, including creating a new OrderDetail record 1202 for any quantity of an item which remains unfilled bythe current transaction. The Package Creation Program (330) can alsoselect and update the Case record 1208 of the scanned case in a mannerconsistent with multi-item package processing, including updating itsStatus to a value such as “empty” when its Quantity is decreased tozero. In many situations over-sized items can be single-item cases,which can be updated to a Quantity of zero and a Status such as “empty”when scanned. However, there can be situations in which an over-sizeditem case contains multiple quantities of an over-sized item SKU. Inthese situations the Package Creation Program (330) can performsingle-item package processing to create a new Package record 1234 foreach over-sized item picked. Package Id, Customer Id, Temperature Code,CDC Id, ePD Shipper Id, RDC Id, and Packing Employee Id, for example,can be written to the new Package record 1234 in the same manner as theycan be in multi-item package processing. The following field updates canbe made differently as a Package record 1234 gets created by single-itempackage processing: Status can be set to a value such as “closed”;Package Bag Holder Id can be set to a value such as “none”; and PackageSize can be set to a value based upon the SKU Size value of the selectedCustomer by SKU Order List data view record 1228 Package Size can be setto a value such as “5” for a SKU Size value such as “large”, PackageSize can be set to a value such as “6” for a SKU Size value such as“extra-large”, or Package Size can be set to a value such as “7” for aSKU Size value such as “LDDH”.

In addition to updating the records involved in a single-item packageprocessing transaction, the Package Creation Program (330) can, forexample, sound a pick confirmation tone, illuminate the pickconfirmation light (84), highlight the single item package indicator(109), print a package label and a packing list, and display a messagein the message field (114) directing the worker to attach the packinglist and package label to the picked item.

Upon hearing a pick confirmation tone and/or seeing the pickconfirmation light after scanning a case label, the worker can pick thecase from the CDC packing station conveyor (44), place it on top of thepackage sealing station top (104), and look at the program displaymonitor (79) of their packing station (45). Following the direction ofthe program, the worker can take the package label from the labelprinter (81) and the packing list from the packing document printer(77), and can look at the label on the picked case to determine if it isa single-item case or a multi-item case. If the case label indicatesthat the case is a single-item case, for example if there is a large “S”printed on it, the worker can take a packing list pouch from the packinglist pouch storage bin (105), peel the back off of its adhesive backside, and attach it to the single-item case, for example, over top ofthe case label. The packing list can be placed inside the packing listpouch by sliding it through its pouch opening, and the package labelthat was printed for the single-item package can be affixed on theoutside of the packing list pouch. The single-item case, with itsattached packing list and package label, can now be considered asingle-item package and can be placed back onto the CDC packing stationconveyor (44). If the case label does not have, for example, a large“S,” or other suitable marking on it to indicate a single-item case, thepicked case can be a multi-item case containing multiple over-sized SKUitems. The worker can scan the case label of the multi-item case ofover-sized SKU items, pick one of the items from the case, and attach apacking list pouch, packing list, and package label to it in manner thatcan be similar to that of a single-item case, except that there is nocase label on the over-sized SKU item to cover with the packing listpouch. The single-item package can be placed on the conveyor (44) andthe case label of the multi-item case of over-sized SKU items can bescanned again. The worker can continue to pick items from the multi-itemcase of over-sized SKU items, creating single-item packages, until thecase is empty or the Package Creation Program (330) displays a messagetelling the worker to redirect the case to a different CDC 1190-1/LDDH1192-1 or local market.

Errors can occur at the destination RDC 1180-1 during the process ofcreating packages 1122. When picking items from cases to createpackages, if a worker sees, for example, a message on their programdisplay monitor (79) that the case the worker just scanned is empty,while there are still items in the case, then the worker can haveuncovered a previously made packing error (an under-packing error). Theworker can, for example, key in the sequence on their packing stationkeypad (80) to run the RDC Package Inspection Report, scan the caselabel of the case in error, key in the quantity difference, and placethe case off to the side of their packing station (45). A RDC PackageInspection Report Program (334) can be initiated. It can use, forexample, the scanned Case Id to select all the Package Id's andQuantities from the Order Detail records 1202 having that Case Id in theCase Id field. The RDC Package Inspection Report Program (334) can usethe selected Package Id's to select the Status, Delivery Shipment Id,and CDC Id of each package from the Package table 1234. The detail ofthe report, as shown on the RDC Package Inspection Report Detail table1242, can list, for example, the Quantity, Package Id, Package Status,Delivery Shipment Id, and CDC Id for each package. The report header, asshown on the RDC/CDC Package Inspection Report Header table 1240, canlist, for example, the ePD Retailer Id and SKU of the case and theQuantity Difference. The RDC Package Inspection Report can be printed onthe packing document printer (77) of the packing station (45), uponwhich it is run, or other suitably configured printer, and it can beused to track down the location of each package regardless of whetherthe package is still in the destination RDC 1180-1 or has left on itsway to a CDC 1190-1 or LDDH 1192-1. If the report contains packages thathave already left the destination RDC 1180-1 on delivery shipments, theRDC Package Inspection Report Program (334) can send data to theprocessing servers, whether remote or local, of the appropriate CDC's1190-1 or LDDH's 1192-1 and can trigger a CDC Package Inspection ReportProgram (336) to run at those CDC's 1190-1 or LDDH's 1192-1. The CDCPackage Inspection Report Program (336) can print a paper report on aCDC or LDDH printer, to be used by CDC or LDDH workers to find andunload packages from SmartBin Units (SBU's) at a CDC 1190-1 or recallpackages from the delivery vehicles of a LDDH 1192-1 for inspection. Theprinted CDC Package Inspection Report can contain, for example, readableSBU Id's or LDDH Delivery Vehicle Id's to assist in finding each packagelisted, and Inspection Authorization Codes, Over Quantity AdjustmentCodes, and Short Quantity Adjustment Codes to unload and enterover/short adjustments for each package listed in a barcode format. ASBU Id/LDDH Delivery Vehicle Id can be listed on the report for apackage if it has already been loaded into a SBU/delivery vehicle.Packages listed on the report that have not been loaded into a SBU oronto a delivery vehicle can have a blank SBU Id/LDDH Delivery VehicleId. An Inspection Authorization Code can consist of concatenated data,which can include, but is not limited to the following: a Package Id, aSBU Id, and a LDDH Delivery Vehicle Id. In FIG. 9D, an exemplary tablecontaining the detailed report is shown on the CDC package inspectionreport detail table (1244). In addition to printing a physical report,once the CDC Package Inspection Report Program (336) is initiated on aCDC's 1190-1 or LDDH's 1192-1 processing server, it can continue to runas a service until all the packages listed on the report, having the CDCId of the processing server on which it can be running, are scanned oruntil the program is aborted. The CDC Package Inspection Report Program(336) can validate each Package Id scanned, during package loading at aCDC 1190-1 or package sorting at a LDDH 1192-1, against the Package Id'slisted on the report having the current CDC Id. The CDC PackageInspection Report Program (336) can alert the CDC 1190-1 or LDDH 1192-1workers, if they scan a package that is listed on the report, to firstinspect the package and confirm that it contains the correct quantity ofthe SKU listed on the report, before continuing to load it into a SBU ata CDC 1190-1 or sort it for delivery at a LDDH 1192-1. The alert canconsist, for example, of an invalid warning tone and a text messagedisplayed on a scanning device display screen or on a SBU display screenin a CDC 1190-1 or a workstation monitor in a LDDH 1192-1. The CDCPackage Inspection Report Program (336), running as a service on theCDC/LDDH server can be aborted by a worker at the CDC 1190-1/LDDH1192-1, or it can be aborted by a worker connecting to the CDC/LDDHserver remotely from a destination RDC 1180-1. Program securitypermissions can be used to control which workers at CDC's 1190-1, LDDH's1192-1, and destination RDC's 1180-1 have the ability to abort the CDCPackage Inspection Report Program (336).

The Package Status and Delivery Shipment Id of each line on the RDCPackage Inspection Report can be used to locate packages in thedestination RDC 1180-1. As a package is located and inspected in thedestination RDC 1180-1, the worker performing the inspection can openthe package and count the number of items, of the SKU listed on the RDCInspection Report, to determine if the package contains the Quantitylisted on the report. If the physical count in the package matches theQuantity on the report, the package can be repacked and the Package Idcan be checked-off on the report. If the physical count doesn't matchthe Quantity on the report, the package can be brought back to the CDCpacking station (45), where the case in error can be located, to berepacked. If the physical count in the package varies from the reportQuantity by exactly the amount of the Quantity Difference on the report,then the workers tracking down the packages on the report can benotified to stop their inspections. If not, the package inspections cancontinue until the full amount of the Quantity Difference is found. Toremove the SKU in error from the package, the worker at the packingstation (45) can, for example, enter a key sequence to initiate aPacking Adjustment Program (338), and can then scan the label on thecase in error and the label on the package in error. The PackingAdjustment Program (338) can reset the values on the Order Detail 1202,Package 1234, and Case 1208 records that were updated when the itemsfrom the case were originally packed into the package. The PackingAdjustment Program (338) can use the scanned Case Id to select the Caserecord 1208 and the scanned Package Id to select the Package record1234. The appropriate Order Detail record 1202 can be selected by theprogram (338) using the scanned Package Id and the SKU and ePD RetailerId from the selected Case record 1208. Status can be set to a value suchas “destination RDC” and the Package Id can be deleted on the OrderDetail record 1202. Status can be set to a value such as “open” andDelivery Shipment Id can be deleted if it had a value on the Packagerecord 1234. The amount that was decremented from the Quantity on theCase record 1208, when the item was originally picked from the case, canbe added back to the Quantity value on that Case record 1208. The Statuson the Case record 1208 can be reset to a value such as “package sort”if it had been set to a value such as “empty”.

The worker can physically remove all the items of the SKU of the case inerror from the package, and place them back in the case. After thePacking Adjustment Program (338) completes the packing adjustment, theworker can scan the case label of the case in error to begin repackingits items. The Package Creation Program (330) can direct the worker topack the identified quantity from the case into the package as if therehad never been a problem. After the packing adjustment transaction andthe subsequent packing transaction, the quantity remaining in the caseshould be in synch with the data on the Case table 1208. The PackingAdjustment Program (338) can also be run against a package that is stillopen to remove a specific SKU from that package.

If a package is not located and inspected until it is already in a CDC1190-1 or LDDH 1192-1, the CDC Package Inspection Report Program (336)can print a hard copy report on the CDC/LDDH printer as previouslydescribed. In most situations, a packing error should be discoveredearly on in the process, before the package leaves the destination RDC1180-1 or when it is scanned during processing at a CDC 1190-1 or LDDH1192-1, but it is possible that a package may be loaded into a SBU oronto a LDDH delivery vehicle before the error is realized. If there arepackages listed on the CDC Package Inspection Report that have alreadybeen loaded onto a LDDH delivery vehicle, the LDDH worker reading thereport can attempt to contact the driver of the delivery vehicle to askthem to look out for the package in question. If there are packageslisted on the report that have already been loaded into SBU's at a CDC1190-1, a CDC worker arriving at the CDC 1190-1 can use the report tosearch for the packages listed using the SBU Id listed with eachpackage. The worker can go to the SBU listed on the report, connect thehands-free barcode scanner that the worker can be using to the SBU, forexample, by plugging it into a scanner port of the SBU, scan theiremployee id card, and then scan the Inspection Authorization Codebarcode on the report to initiate a CDC Package Adjustment Program (350)of an ePD SBU Application running on a server for the current CDC1190-1. The CDC Package Adjustment Program (350) can use the Package Idand SBU Id embedded in the scanned Inspection Authorization Code toretrieve the package listed on the report from the SBU. Once the packagerequiring inspection is retrieved, the CDC worker can perform theinspection in the same manner as a package inspection performed in thedestination RDC 1180-1, but if a difference is found the package is notreturned to the packing station (45) in the destination RDC 1180-1 to berepacked. If the package was over-packed (meaning a greater quantity wasphysically placed in the package) the worker can remove the extra itemsto make the physical quantity match the quantity listed on the CDCPackage Inspection Report and the package's packing list. The worker cansend the extra quantity of the item back to the destination RDC 1180-1with the report on a CDC reverse shipment originating from the CDC1190-1 to its destination RDC 1180-1. When the item is received at thedestination RDC 1180-1 it can be physically added back into the casethat was set aside because of the error. Adjustments to the related datarecords are not required to correct an over-pack error because thephysical situation has been corrected to match the data. If the packagewas under-packed (meaning a lesser quantity was physically placed in thepackage), the package does not need to be changed physically except thatthe packing list containing the under-packed item can be adjusted byhand to show the correct quantity. The CDC worker can update thequantities on the related Order Detail 1202 and Case 1208 records toaccount for the difference by scanning the short adjustment barcodecorresponding to the package on the report and entering the quantityadjustment that was made, for example, on the SBU keypad. The CDCPackage Adjustment Program (350) can send the data from the CDC's 1190-1processing server to update the Order Detail 1202 and Case 1208 tablesin the database on the destination RDC's 1180-1 processing server. TheQuantity on the Case record 1208 can be increased by the shortadjustment quantity and the adjusted quantity should match the physicalquantity remaining in the case that was set-aside at the packing station(45) in the destination RDC 1180-1. A new Order Detail record 1202 canbe created to split the quantity on the existing record 1202, resultingin the existing record 1202 retaining its Package Id and Status andhaving an adjusted Quantity to match the actual physical quantity thatwas in the package and the new record 1202 having the same Order Id, aQuantity equal to the short adjustment quantity, a Status value such as“destination RDC”, and no Package Id value. The under-packed itemquantity can be picked from a case and packed into a package at thedestination RDC 1180-1 as the Package Creation Program (330) attempts tosatisfy the demand of the new Order Detail record 1202 created by thetransaction used to correct the under-pack error.

Following the creation of packages step 1122, delivery shipments ofpackages to be delivered to a CDC 1190-1 or LDDH 1192-1 can be createdat the destination RDC 1180-1 as illustrated in step 1124. To create ePDdelivery shipments, one or more workers at a destination RDC 1180-1 canbe stationed between a CDC packing station conveyor (44) and a CDC feedof the CDC package conveyor (47A) to organize packages bound for aparticular CDC 1190-1 or LDDH 1192-1 into an ePD delivery shipment. AnePD delivery shipment can consist of a group of packages bound for oneCDC 1190-1 or LDDH 1192-1 on one trailer or other suitable cargocarrying transport. A worker creating an ePD delivery shipment can use,for example, a hands-free barcode scanning device communicating with theworkstation running their instance of a Delivery Shipment CreationProgram (340) to scan package label barcodes as the worker pickspackages from the CDC packing station conveyor (44) and places them intocargo cages sitting on the CDC feed conveyor (47A) at which the workeris working. In one aspect of the invention, boxes, bins, crates or othercontainers known in the art can be employed instead of cargo cages.Cargo cages can be used to organize packages bound for the same CDC1190-1 or LDDH 1192-1 into an ePD delivery shipment. A cargo cage can bea container designed to hold many small and medium sized packages. Forillustration, each side of a cargo cage can be constructed of, forexample, 1/16^(th) inch thick plastic coated metal wires, which crosseach other perpendicularly every few inches. The metal wires can bebound into the four perpendicularly intersecting side edge beams thatform each rectangular side of the cargo cage. The sides of the cargocage can be attached to each other by metal linking clasps sized to fitaround the width of two edge beams. Linking clasps can be attached neareach corner of a cargo cage side panel to bind the side panels to eachother and to the cargo cage bottom panel to form a cargo cage. Thebottom panel of the cargo cage can consist of two panels, constructed ina manner that can be similar to the way the side panels are constructed,with shock absorbers between the two panels at each corner and at themidpoint of each side. Each shock absorber can consist of, for example,a spring made of metal or other suitable composite, a few inches high,and a few inches in diameter. Linking clasps can also be used to binddifferent cargo cages together to form a grouping of cargo cages for adelivery shipment. A cargo cage label plate holder can be built into theupper corner of at least one of the sides of each cargo cage. A cargocage label plate holder can be a frame with a hollow slot in which alabel plate can be inserted (and subsequently removed) to label one ormore grouped cargo cages as a delivery shipment.

A worker can create a new ePD delivery shipment for a CDC 1190-1 or LDDH1192-1 by first selecting an option on the program menu of the DeliveryShipment Creation Program (340) such as the “create new deliveryshipment” menu option. The Delivery Shipment Creation Program (340) cancreate and print a new delivery shipment label for the deliveryshipment. The delivery shipment label can contain the Delivery ShipmentId in both a barcode and a readable format and the CDC Id of thedelivery shipment in readable format. The worker can, for example, takethe delivery shipment label from the label printer, affix it to adelivery shipment label plate, and place the label plate in the labelplate holder of an empty cargo cage. The label plate can be anon-descript rectangular card, made of plastic, metal or another firmand durable material, upon which a label can be affixed. The uniquedelivery shipment label on the label plate can make it useful inidentifying a delivery shipment and all its associated packages. Theworker can continue creating the delivery shipment, by scanning, forexample, their employee id card, scanning the label on the deliveryshipment label plate, picking a sealed package from the CDC packingstation conveyor (44), and scanning the barcode label on the package, asthe worker places it into the cargo cage. The worker can continue topick sealed packages from the CDC packing station conveyor (44), scanthe package labels, and place the packages into the cargo cage, untilthe cargo cage is filled. Additional cargo cages can be built from cargocage bottom panels, side panels, and linking clasps which can be storednear the CDC feed conveyor (47A). The cargo cages can be attached nextto or on top of cargo cages already filled for the current CDC (1190-1)or LDDH (1192-1), as more multi-item packages get added to the deliveryshipment. The worker can identify single-item packages to be picked fromthe CDC packing station conveyor (44) by their packing list pouches. Theworker can pick single-item packages, scan their package labels, andplace them on the CDC feed conveyor (47A) next to or on top of the cargocages bound for the same CDC 1190-1 or LDDH 1192-1. The worker cancontinue to load multi-item packages into cargo cages and placesingle-item packages next to or on top of the cargo cages on the CDCfeed conveyor (47A) until there are enough to fill an entiretrailer-load. The amount of cargo cages and single-item packages neededto fill a trailer-load can be measured in length by ruler markings onthe sides of the CDC feed conveyor (47A), similar to the ones used onthe sides of retailer dock conveyors. In one embodiment, cargo cages canbe stacked, for example, up to three units high to fit into trailers.The Delivery Shipment Creation Program (340) can associate the scannedmulti-item and single-item package with the current delivery shipmentuntil the worker selects a menu option to end the current deliveryshipment.

The Delivery Shipment Creation Program (340) can create a new record onthe Delivery Shipment table 1238 as a worker physically creates each newdelivery shipment. The Delivery Shipment Creation Program (340) cancreate the new Delivery Shipment records 1238 having the followingexemplary field values: a unique Delivery Shipment Id can be created byconcatenating, for example, the RDC Id+CDC Id+current date+a sequentialthree digit number; Status can be set to a value such as “in RDC”; ePDShipper Id and RDC Id can be set to the values for the currentdestination RDC 1180-1; CDC Id and Temperature Code can be set to thevalue from the Package record 1234 of the first scanned package; RDCEmployee Id can be set to the value from the scanned employee id card;and the other fields can be created without values. The Package recordof each package scanned into a delivery shipment can be updated to setStatus to a value such as “delivery shipment” and Delivery Shipment Idcan be set to the value on the newly created delivery shipment record towhich the package was added. As packages are scanned to be added to adelivery shipment, the Delivery Shipment Creation Program (340) canvalidate the CDC Id value of the scanned package to verify that itmatches the value on the current Delivery Shipment record 1238. If apackage having a different CDC Id is scanned by mistake the DeliveryShipment Creation Program (340) can signal an error, for example, bysounding an invalid warning tone and displaying a message, on theworkstation running the Delivery Shipment Creation Program (340),indicating that the scanned package is for a different CDC 1190-1 orLDDH 1192-1.

In a further aspect of the invention, full-trailer-load deliveryshipments can be created to meet the frequency of tractor-trailersleaving for the local market of those delivery shipments' CDC's 1190-1or LDDH's 1192-1. However, if necessary, delivery shipments bound fordifferent CDC's 1190-1 or LDDH's 1192-1 within the same local market canbe combined together into a full-trailer-load. To combine differentdelivery shipments together into one full-trailer-load, the workerscreating the delivery shipments on nearby CDC feed conveyors (47A) cancollaborate with each other to move their delivery shipments in closeproximity of each other. A local market feed of a CDC package conveyor(47B) can be made up of different independent conveyor sections whichcan be moved in either direction or remain motionless, independently ofeach other. There can be local market feed conveyor sections (47B) inbetween each of the different CDC feed conveyors (47A), and between theCDC feed conveyors (47A) and either a left side feed of a packageconveyor (46A) or a right side feed of a package conveyor (46B).Multiple delivery shipments can be organized into a full-trailer-load bymoving the CDC feed conveyors of different CDC's and LDDH's (47A) andthe different sections of the local market feed conveyor (47B) inbetween those CDC feed conveyors (47A) forward and/or backward in acoordinated effort to align the different delivery shipments in closeproximity of each other, in a desired sequence. One delivery shipmentlabel plate can be located on the back of the last cargo cage, at thetrailing end of each delivery shipment. A small amount of space can beleft between the different delivery shipments of a full-trailer-load, toensure that they can be visibly seen as separate delivery shipmentswithin the same full-trailer-load, and to allow access to the label oneach delivery shipment label plate.

When a full-trailer-load of delivery shipments has been assembled oneither the CDC feed (47A) or the local market feed (47B) of a CDCpackage conveyor, one of the workers involved in organizing thefull-trailer-load, can use the motion controls of the local market feedpackage conveyor (47B) to coordinate all of the conveyor sections of thelocal market feed package conveyor (47B) in between thefull-trailer-load and a side package conveyor (either left-side 46A orright-side 46B) to move the full-trailer-load onto the side packageconveyor (46A or 46B). The delivery shipments of a full-trailer-load cantravel together, in close proximity to each other, from the side packageconveyor (46A or 46B) onto the merging section of the package conveyor(46C), and then onto the outbound section of the package conveyor (46D).

There is shown in FIG. 8A, a detailed layout of an exemplary localmarket shipping dock area within a RDC. The exemplary local marketshipping dock area of FIG. 8A can contain: a package conveyor—outboundsection 46D, a local market shipping dock conveyor 48, a local marketshipping dock conveyor extension 48A, a local market shipping dock (bay)door 50, a package diverting conveyor unit (inactive position) 208, apackage diverting conveyor unit (loading position) 208A, a locking pin(in locking slot) 210, a pivot pin 212, a pivot support base 214, aninactive locking slot 216, a loading locking slot 218, and a localmarket shipping dock workstation (& printer) 220. There is also shown inFIG. 8A, a tractor 200 having a trailer 202, the trailer 202 beingparked with its rear toward a RDC exterior wall 206. Within the trailer202 is a trailer conveyor 204, which can facilitate loading andunloading of cargo.

The curved-shaped package diverting conveyor unit (208) can be similarto the case diverting section of the RDC inbound conveyor (38) in itscomposition and function. Referring to FIG. 8A, there can be a packagediverting conveyor unit (208) for each local market shipping dockconveyor (48). Package diverting conveyor units (208) can be attached tothe outside edge of the outbound section of the package conveyor (46D)and can be locked into one of two positions by a locking pin (210). Theconveyor units (208) can be locked into the loading position tointercept and divert packages from the package conveyor (46D) to a localmarket shipping dock conveyor (48) or into the inactive position toremain out of the way as full-trailer-loads pass by on the outboundsection of the package conveyor (46D). When it is in the loadingposition, the leading end of the package diverting conveyor unit (208)can sit over top of the package conveyor (46D) and its trailing end cansit over top of the local market shipping dock conveyor (48). When it isin the inactive position, the unit (208) can sit completely over top ofits pivot support base (214), with only its leading edge resting on theouter side edge of the package conveyor (46D). When a package divertingconveyor unit's locking pin (210) is unlocked, the unit (208) can beshifted between the inactive position and the loading position bypushing or pulling it in the desired direction until its locking pin(210) lines up with the inactive locking slot (216) or the loadinglocking slot (218). Locking slots can be built into the side edges ofthe package conveyor (46D). The conveyor unit (208) can pivot betweenthe two positions on support roller wheels attached to its bottom. Thesupport roller wheels can allow the bulky conveyor unit (208) to glideeasily, back and forth, on top of its pivot support base (214) and thepackage conveyor (46D). The unit's pivot pin (212) can anchor the unit(208) on a fixed pivot axis as it moves between its two positions. Whenthe unit's leading end is locked into the loading position, its trailingend can be aligned over top of the local market shipping dock conveyor(48).

As a full-trailer-load of delivery shipments moves along on the outboundsection of the package conveyor (46D) and passes by a worker responsiblefor loading delivery shipments onto outbound tractor-trailers, theworker can inspect the delivery shipment label plate on the back of thetrailing-end of the full-trailer-load's last delivery shipment. Workersresponsible for loading delivery shipments onto outboundtractor-trailers can be organized, for example, so that each one coversa few adjacent local market shipping dock conveyors (48) from whichtractor-trailers bound for one specific local market can be loaded. Whenone of these workers sees a full-trailer-load containing a deliveryshipment bound for one of the CDC's 1190-1 or LDDH's 1192-1 of theirlocal market (one worker may also cover one or more local markets), theworker can use a package diverting conveyor unit (208) to move thefull-trailer-load of delivery shipments onto one of their empty localmarket shipping dock conveyors (48).

To move a full-trailer-load of delivery shipments from the outboundsection of the package conveyor (46D) onto a local market shipping dockconveyor (48), the worker can lift the package diverting conveyor unit'slocking pin (210) out of the inactive locking slot (216), push theconveyor unit (208) from the inactive position to the loading position,slide the locking pin (210) into the loading locking slot (218), andswitch on the power of the conveyor unit (208) to start its conveyormotion. The worker can start the local market shipping dock conveyor(48) upon which the worker positioned the conveyor unit (208) in theloading direction. The full-trailer-load can move from the packageconveyor (46D) up onto the conveyor unit (208). The full-trailer-loadcan follow the conveyor unit's (208) curved path, moving down onto thelocal market shipping dock conveyor (48), and can be moved on the localmarket shipping dock conveyor (48) from its back end toward the localmarket shipping dock conveyor extension (48A) at its front end. Afterthe full-trailer-load has been moved onto the dock conveyor (48)completely, the worker can stop the motion of the dock conveyor (48) andthe conveyor unit (208) and can reposition the conveyor unit (208) backto the inactive position. After repositioning the package divertingconveyor unit (208), the worker can return to the outbound section ofthe package conveyor (46D) to search for another full-trailer-load ofdelivery shipments bound for their local market. The worker can continuethis sub-process until a tractor-trailer driver signals that atractor-trailer is ready to accept delivery shipments.

Following the creation of the delivery shipments of packages, step 1124,the packages can be ready to be shipped to one or more CDC's 1190-1 orto one or more LDDH's (1192-1), as illustrated in step 1128 and step1126 respectively. After the trailer door closes at the end of unloadingretailer shipments onto a local market receiving dock conveyor (14), theprocess of receiving retailer shipments into an origination RDC 1180-1(in the current illustrative example RDC 1180-1 can serve as anorigination RDC for cases of items received into that RDC from retailerfulfillment sites 1194-1 in a local market served by RDC 1180-1, in astep similar to step 1110) can be complete. Referring to FIG. 3, thetractor-trailer driver can drive a tractor-trailer (200 & 202) from thelocal market receiving dock bay (12) to a local market shipping dock bay(50) corresponding to the local market to which the driver travels. Thetractor-trailer (200 & 202) can be backed up to the local marketshipping dock door (50) and the driver can signal the loading workers atthe destination RDC 1180-1 (in the current illustrative example RDC1180-1, can now serve as a destination RDC for delivery shipments ofpackages to be delivered to one or more CDC's 1190-1 or LDDH's 1192-1 inthe local market to which the driver travels) to let them know that anempty tractor-trailer (200 & 202) has arrived. The driver can refuel thetractor-trailer (200 & 202), while a RDC worker loads afull-trailer-load of delivery shipments onto the driver'stractor-trailer (200 & 202) from the local market shipping dock conveyor(48) at which the driver arrived. The worker who loads the trailer (202)can be the same worker who moved the full-trailer-load onto that dockconveyor (48). With reference to FIG. 11B, the worker can open the localmarket shipping dock door (50) and initiate a Delivery Shipment Program(342) by, for example, scanning the barcode on their employee id card,scanning the Trailer Id barcode on the trailer door label, and scanningthe Delivery Shipment Id barcode on the label plate of the deliveryshipment farthest away from the shipping dock door (50). The DeliveryShipment Program (342) can read the CDC Id from the record on theDelivery Shipment table 1238, having the scanned Delivery Shipment Idand can use it to retrieve the values of the Type, CDC Server ConnectionScript, Primary Contact Number, Secondary Contact Number, and Temp CodeReservation Override fields from the CDC table 1252. If the Type valueretrieved is a value such as “LDDH”, the Delivery Shipment Program (342)can determine the quantity of multi-item packages (in cargo cages) andsingle-item packages by selecting records from the Package table 1234having the scanned Delivery Shipment Id, and grouping and subtotalingthose records by Package Size. This calculated package count informationcan be saved along with the Delivery Shipment Id by the DeliveryShipment Program (342). This saved information can later be printed onthe Delivery Shipments Report. If the Type value retrieved is a valuesuch as “CDC”, the Delivery Shipment Program (342) can use the retrievedCDC Server Connection Script value to establish a remote connection tothe database on the server of the destination CDC 1190-1. The DeliveryShipment Program (342) can use the remote connection to retrieve thatCDC's 1190-1 available SBU bin capacity for each Bin Size, from theUnreserved Bins data view.

With reference to FIG. 10A, an Unreserved Bins data view 1305, can becreated by subtracting the Quantity of bins of each Bin Size-TemperatureCode combination on a Reserved Bins data view 1303 from the Quantity ofthe corresponding Bin Size-Temperature Code combination on a BinAvailability data view 1301, and then adding the Quantity Adjustment ofthe corresponding Bin Size-Temperature Code combination on a Pending BinConfiguration Adjustments table 1304. The Bin Availability data view1301 can be created from an underlying Bin Inventory table 1300 byselecting records having a Status such as “available”, grouping thoseselected records by Bin Size and Temperature Code, and then subtotalinga count of the records within each group. The Reserved Bins data view1303 can be created from an underlying Bin Reservation table 1302, forexample, by selecting, grouping, and subtotaling the Quantity on recordsof each Bin Size-Temperature Code combination that do not have a Statussuch as “filled”.

After retrieving the available bin capacity for each BinSize-Temperature Code combination from the Unreserved Bins data view1305, the Delivery Shipment Program (342) can compare it against thenumber of packages of each Package Size-Temperature Code combination inthe current delivery shipment to determine the extent of the CDC's1190-1 available bin capacity to receive the packages of the currentdelivery shipment. The Delivery Shipment Program (342) can select andgroup Package records 1234 having the scanned Delivery Shipment Id byPackage Size and Temperature Code. The program (342) can subtotal therecord count of each group of Package records 1234 to determine thenumber of packages of each Package Size-Temperature Code combination inthe current delivery shipment. The Delivery Shipment Program (342) canadd a new record to the Bin Reservation table 1302 (on the current CDC's1190-1 database server) to reserve, for the current shipper, theQuantity of each Bin Size-Temperature Code combination needed to receivethe bulk delivered packages of the delivery shipment, up to theavailable bin capacity found on the Unreserved Bins data view 1305. Eachnew Bin Reservation record 1302 can be created with, for example, theBin Size, Temperature Code, and Quantity being reserved, the ePD ShipperId of the current shipper, a Reservation Date/Time equal to the currentdate/time, Trailer Loading Employee Id equal to the value scanned fromthe worker's employee id card, and a Status value such as “new”. TheDelivery Shipment Program (342) can track the bin capacity shortage ofeach Bin Size-Temperature Code combination in a program variable. Ifbins are available to be reserved for the entire Quantity of a PackageSize-Temperature Code combination, the program variable holding the bincapacity shortage for the corresponding Bin Size-Temperature Codecombination can be zero. The ePD Delivery Application can allowdifferent shippers to reserve bin space in a CDC 1190-1, as there may bemultiple shippers shipping bulk delivered packages from differentdestination RDC's (the RDC's of shippers other than the one shipperdepicted in the illustrative example of FIG. 2 are not shown) to thesame CDC 1190-1. In another embodiment of the invention, a given CDC canbe run by a single shipper, and can receive delivery shipments from onedestination RDC 1180-1 only, negating the need to reserve bin space.

The Delivery Shipment Program (342) can also update the DeliveryShipment record 1238 of the scanned delivery shipment on the currentRDC's 1180-1 database server by, for example, changing its Status to avalue such as “in-transit”, writing the scanned employee id into theTrailer Loading Employee Id field, writing the scanned trailer id intothe Trailer Id field, and writing the current date and time into aDelivery Shipment Loading Date/Time field. The update can associate thedelivery shipment (and all the packages of ordered items containedtherein) with the trailer (202) upon which it will be loaded.

If the Delivery Shipment Program (342) does not find enough unreservedSBU bins having a Temperature Code value such as “standard” to receiveall the packages having a Temperature Code value such as “standard”, itmay attempt to reserve SBU bins having a Temperature Code value such as“refrigerated” to receive “standard” Temperature Code packages. Todetermine whether it is able to reserve “refrigerated” Temperature CodeSBU bins for “standard” Temperature Code packages, the program (342) cancheck the Temp Code Reservation Override field that was retrieved fromthe CDC table 1252 for current CDC 1190-1 and can compare the percentagelisted against the unreserved refrigerated bins ratio. The unreservedrefrigerated bins ratio can be calculated by dividing the sum of theQuantity values on the Unreserved Bins data view records 1305 having aTemperature Code value such as “refrigerated” by the total count of binson the Bin Inventory table 1300 having a Temperature Code value such as“refrigerated”. If the Temp Code Reservation Override percentage is lessthan the unreserved refrigerated bin ratio, then the Delivery ShipmentProgram (342) can begin to reserve “refrigerated” Temperature Code binsup until the unreserved refrigerated bins ratio becomes less than orequal to the Temp Code Reservation Override value for the current CDC1190-1. The unreserved refrigerated bins ratio can be decreased as“refrigerated” bins are reserved.

If the Delivery Shipment Program (342) cannot reserve enough bins toreceive all the bulk delivered packages of the delivery shipment, it caninitiate or cause to be initiated, a Configuration Adjustments ReportProgram (344) to determine the SBU bin configuration adjustments thatshould be made to increase the number of bulk delivered packages fromthe current delivery shipment which are able to be received into the CDC1190-1. When the Delivery Shipment Program (342) calls or causes theConfiguration Adjustments Report Program (344) to be called, it can passits program variables containing the bin capacity shortage of each BinSize-Temperature Code combination as inputs. The ConfigurationAdjustments Report Program (344) can use the bin capacity shortageinformation and its program rules to effectively make configurationadjustments by updating the Pending Bin Configuration Adjustments table1304, and in some situations updating the Bin Inventory table 1300.While the Configuration Adjustments Report Program (344) does not makethe actual bin configuration adjustments, it can effectively make theadjustments by updating the data views used to determine binavailability, to take into account the bin configuration adjustmentsthat will be made. The actual bin configuration adjustments can bephysically made to SBU's in the CDC 1190-1, in step 1140, by CDC workersusing the Configuration Adjustments Report. The ConfigurationAdjustments Report Program (344) can also add records to the BinReservation table 1302 to reserve the bins made available by itsconfiguration adjustments for the packages of the current deliveryshipment.

The program rules of the Configuration Adjustments Report Program (344)can be followed to effectively make bin configuration adjustments andbin reservations to resolve the bin capacity shortage of each PackageSize-Temperature Code combination in a serial manner. The bin capacityshortage of each Package Size-Temperature Code can be processed one at atime, in the sequence of the Configuration Adjustments Report Program's(344) priority rules, and each subsequent bin configuration adjustmentcan be calculated based upon prior bin configuration adjustment updatesand bin reservation updates. Package Size-Temperature Code bin capacityshortages can be processed in priority sequence by Temperature Code,starting with a value such as “freezer”, then a value such as“refrigerated”, and finishing with a value such as “standard”. WithinTemperature Code priorities, Package Size-Temperature Code bin capacityshortages can be processed by a pre-defined Package Size prioritysequence, for example, “4”, “3”, “6”, “2”, “5”, “1”. To resolve eachshortage, the Configuration Adjustments Report Program (344) can attemptto make a division configuration adjustment before making aconsolidation configuration adjustment. Bin Sizes such as “5” and “6”can be considered separately from the other Bin Sizes when making binconfiguration adjustments, as they can be part of separate master bins.

To effectively make a division configuration adjustment, theConfiguration Adjustments Report Program (344) can search the UnreservedBins data view 1305 for the Quantity of Bin Size-Temperature Codecombinations larger than the Package Size of the PackageSize-Temperature Code bin capacity shortage that it is trying toresolve. It can start with the next largest bin size, greater in sizethan the Package Size for which it is searching, before searching forlarger Bin Sizes in increasing size sequence. The ConfigurationAdjustments Report Program (344) can determine how many bins, of the BinSize corresponding to the current Package Size, it can make fromdividing one bin of the selected Bin Size. It can, for example, multiplythe total number of bins, of the selected Bin Size found on theUnreserved Bins data view 1305, by the number of bins, of the Bin Sizecorresponding to the current Package Size, that can be created from eachone of those selected bins. The Configuration Adjustments Report Program(344) can also determine if there can be a remainder Bin Size left afterdividing the selected unreserved bins. The Configuration AdjustmentsReport Program (344) can update the existing record 1304 or create a newrecord on the Pending Bin Configuration Adjustments table 1304 toaccount for a positive adjustment to the Quantity of bins of the BinSize-Temperature Code combination that will be created when the binconfiguration adjustment is physically made at the CDC 1190-1. TheConfiguration Adjustments Report Program (344) can also update or createanother record on that table 1304 to account for a negative adjustmentto the Quantity of bins of the Bin Size-Temperature Code combinationthat will be divided to create the additional smaller bins. If a numberof bins will be created from the remainder of each bin configurationadjustment, a new record can be added or a Quantity update to anexisting record can be made to the Pending Bin Configuration Adjustmentstable 1304 to account for the positive adjustment to the Quantity ofbins of the Bin Size-Temperature Code combination of the remainder BinSize. The Configuration Adjustments Report Program (344) can also createa new record on the Bin Reservation table 1302 to reserve bins for theQuantity of additional packages, of each Package Size-Temperature Codecombination in the current delivery shipment, that will be able to bedelivered because of the newly made pending bin configurationadjustments.

If the Configuration Adjustments Report Program (344) was unable toresolve the entire bin capacity shortage of the Package Size-TemperatureCode combination using the first Bin Size-Temperature Code combinationit selected from the Unreserved Bins data view 1305, it can select theUnreserved Bins record 1305 having the next largest Bin Size for thesame Temperature Code, and can follow the same processing logic toresolve the remaining shortage. If there is still a shortage aftertrying to divide the largest possible Bin Size applicable to thatPackage Size (single-item packages for stationary bins can be consideredseparate from multi-item packages for revolving bins), the ConfigurationAdjustments Report Program (344) can attempt to effectively make aconsolidation configuration adjustment to resolve the remainingshortage. To effectively make a consolidation configuration adjustment,the Configuration Adjustments Report Program (344) can select all therecords from the Bin Inventory table 1300 having the Temperature Code ofthe current Package Size-Temperature Code combination and a Status suchas “available” in a subquery. It can then select the records from thatsubquery for which there is more than one record having the same MasterBin Id. The Configuration Adjustments Report Program (344) can readthrough the Configuration Codes of those selected subquery records todetermine if the selected bins can be consolidated together to receive apackage of the current Package Size. If the Configuration AdjustmentsReport Program (344) determines, using its configuration logic rules,that two or more selected Bin Inventory records 1300 having the sameMaster Bin Id can be consolidated together to create a bin to meet thesize of the current Package Size, then the Configuration AdjustmentsReport Program (344) can search the Unreserved Bins data view 1305 tomake sure that the selected Bin Inventory records 1300 are not alreadyreserved indirectly on the Bin Reservation table 1302. If theConfiguration Adjustments Report Program (344) is able to find a bin onthe Unreserved Bins data view 1305 to match the Bin Size of each BinInventory record 1300 involved in the possible bin configurationadjustment, then there can be enough unreserved bins to accept incomingpackages without the selected Bin Inventory records 1300. The program(344) can update the Status of the selected Bin Inventory records 1300to a value such as “configuration reserved”. The program (344) can alsomake updates to the Pending Bin Configuration Adjustments table 1304 toaccount for both the positive and negative adjustments to the Quantityof the Bin Size-Temperature Code combinations that will be created andremoved when the consolidation bin configuration adjustment isphysically made at the CDC 1190-1. A new Bin Reservation record 1302 isnot created to reserve bins for a consolidation bin configurationadjustment, since a “hard allocation” reservation was made directly tothe Bin Inventory table 1300 through the Status update. The Statusupdate that can be made to the selected Bin Inventory record 1300 for apending consolidation bin configuration adjustment can automatically,flow through to the Bin Availability data view 1301 that is created fromthe Bin Inventory table 1300 and the Unreserved Bins data view 1305 thatis created from the Bin Availability data view 1301. A Loading Program(356), which can be run in a CDC 1190-1 when packages are being loadedinto SBU bins, will not allow packages to be loaded into bins that havea Status value such as “configuration reserved”. A “hard allocation” (areservation of specific bins) can be made for consolidation binconfiguration adjustments, because unlike a division bin configurationadjustment in which any available bin of a larger size can be dividedinto smaller bins, a consolidation bin configuration adjustment canrequire that two or more available smaller bins be adjacent to eachother within the same master bin to be configured together into a largerbin. Reserving specific bins can prevent a bulk delivered package frombeing loaded into a bin, and can thus preserve that bin's ability to beconsolidated with one or more adjacent bins to create a larger bin.

Once the Configuration Adjustments Report Program (344) finishes aconsolidation adjustment for a given Package Size-Temperature Codecombination, it can attempt to find another set of selected BinInventory records 1300 to effectively make another consolidationadjustment until the entire bin capacity shortage for that PackageSize-Temperature Code combination is fully resolved, or until it isunable to find a set of Bin Inventory records 1300 which can beconsolidated to hold a package of the current Package Size-TemperatureCode. Once either of these two situations occurs, the ConfigurationAdjustments Report Program (344) can begin to process the bin capacityshortage of the next Package Size-Temperature Code combination. As itfinishes effectively making all the bin configuration adjustments thatit is able to make to resolve a bin capacity shortage, the ConfigurationAdjustments Report Program (344) can continue to save the remaining bincapacity shortage value for each Package Size-Temperature Codecombination in a program variable.

The Configuration Adjustments Report Program (344) can print, or causedto be printed, a hard copy report for the CDC workers of the ePD shipperon, for example, a report printer in the CDC 1190-1. It can also send,or cause to be sent, an e-mail/text pager message to the primary andsecondary cell phone/text pager device associated with that CDC 1190-1to notify the CDC workers of that CDC 1190-1 that a ConfigurationAdjustments Report has printed. Configuration Adjustments Reports fordifferent shippers can be printed on the same CDC report printer, but ashipper's CDC workers can identify which report to use by looking forthe ePD Shipper Id in the report header. Each Configuration AdjustmentsReport can contain only the bin configuration adjustments needed toreceive the packages of that shipper.

After the Configuration Adjustments Report Program (344) finishes itsbin configuration processing, it can initiate a Shipment AdjustmentsReport Program (345), passing the remaining bin capacity shortage valuesto the program (345) as program inputs. If all of the remaining bincapacity shortage values equal zero, the Shipment Adjustments ReportProgram (345) can send a message to the Delivery Shipment Program (342)to confirm that no shipping adjustments are required. If there is atleast one remaining bin capacity shortage value greater than zero, theShipment Adjustments Report Program (345) can create a report listingthe total quantity of packages of each Package Size-Temperature Codecombination that should be removed from the current delivery shipment toprevent sending more packages than the CDC 1190-1 has the capacity toaccept. A barcode containing an identifier of the program variableholding the bin capacity shortage value of each Package Size-TemperatureCode combination can be printed with each report line. The barcodes canbe used to initiate the action of removing packages from the deliveryshipment. The Shipment Adjustments Report Program (345) can, forexample, sound an error tone, and/or light the local market shippingdock workstation warning light (located at the local market shippingdock workstation (220) processing the current delivery shipment), printa hard copy of the report at, for example, the workstation's (220)printer, and send a message to the Delivery Shipment Program (342) toconfirm that the report has been sent to the printer.

A worker can retrieve the Shipping Adjustments Report from theworkstation's printer (220) and can scan the barcode on the report nextto the first report detail line. The worker can pick the number ofpackages, of the Package Size-Temperature Code combination listed onthat report line, out of the current delivery shipment, scanning thepackage label barcode of each one as the worker places it aside thelocal market shipping dock conveyor (48). The Shipment AdjustmentsReport Program (345) can use the scanned Package Id to validate that thePackage Size and Temperature Code of the scanned package match the BinSize and Temperature Code of the last identifier scanned on the ShipmentAdjustments Report. If the scanned package fails validation, the program(345) can, for example, sound an error tone, light the local marketshipping dock workstation warning light, and/or display a message on theworkstation's program display monitor (220) that the scanned packagedoes not match the delivery shipment adjustment scanned on the report.If the scanned package passes validation, the Shipment AdjustmentsReport Program (345) can, for example, sound a confirmation tone and canupdate the Package record 1234 of the scanned package, setting Statusfrom a value such as “delivery shipment” back to a value such as“closed” and deleting the Delivery Shipment Id. The program (345) canalso decrement the bin capacity shortage value of the barcode indicatorscanned on the report by one for each package successfully removed fromthe delivery shipment. The removed packages which have been set asidecan later be moved back to the CDC feed conveyor (47A) from which thosepackage came, after the worker is finished loading all of the deliveryshipments into the outbound trailer (202). The worker can continue toscan the barcodes listed on the report and remove packages as requireduntil the entire quantity of packages of each Package Size-TemperatureCode listed on the Shipping Adjustments Report has been removed from thedelivery shipment. After finishing working through the report, theworker can, for example, scan a confirmation barcode at the bottom ofthe report to confirm that all the adjustments have been made. TheShipment Adjustments Report Program (345) can validate that the value ofeach bin capacity shortage program variable has been decremented to zeroand can sound a confirmation tone.

If there is more than one delivery shipment on the local market shippingdock conveyor (48), the worker can scan the Delivery Shipment Id barcodeon the cargo cage of the next delivery shipment to repeat the deliveryshipment loading process previously described, for the remainingdelivery shipments. The delivery shipments can be scanned in a sequencestarting with the one farthest from the local market shipping dock door(50). After all the delivery shipments have been processed, the workercan select the program menu option to end the Delivery Shipment Program(342) and the Delivery Shipments Report can print on the workstation'sreport printer (220). The Delivery Shipments Report can list thedelivery shipments that will be physically loaded onto the trailer (202)in the sequence in which they were scanned (which can also be thesequence in which they will be unloaded). The Delivery Shipments Reportcan provide guidance to the driver transporting delivery shipments toCDC's 1190-1 and/or LDDH's 1192-1 within a local market, by listing thedestination CDC 1190-1 or LDDH 1192-1 of each delivery shipment on thetractor-trailer in unloading order. The CDC Id, CDC Description, CDCaddress related fields (for example, an Address 1 field, an Address 2field, a City field, a State field, and a Zip field), Primary ContactNumber, Secondary Contact Number, the total number of multi-itempackages in the delivery shipment, and the total number of single-itempackages in the delivery shipment can be listed on the DeliveryShipments Report in a readable format for each CDC 1190-1/LDDH 1192-1listed on the report. The Delivery Shipment Id, Temperature Code and thetotal number of packages of each Package Size in the delivery shipmentcan be printed, for example, in a single parseable barcode on theDelivery Shipments Report for each CDC 1190-1/LDDH 1192-1 report item.The total number of packages of each Package Size and the total numberof multi-item packages and single-item packages for a delivery shipmentcan have been calculated when the program (342) originally selectedrecords from the Package table 1234 for that delivery shipment. CDCrelated information can have been retrieved from the CDC table 1252using the CDC Id embedded in the scanned Delivery Shipment Id barcode.

After retrieving the Delivery Shipments Report from the report printer(220), a worker can open the trailer door, move the conveyor extensionof the local market shipping dock conveyor (48A) into the horizontalloading position, start the trailer conveyor (204) in the loadingdirection, and then start the local market shipping dock conveyor (48)in the loading direction. The system of conveyors can move the deliveryshipments onto the trailer conveyor (204). The RDC worker can stop theconveyors (204, 48A & 48), reposition the conveyor extension (48A) tothe vertical delivery preparation position, and close the trailer door.The worker can hand the Delivery Shipments Report to the tractor-trailerdriver, and the driver can depart for the first CDC 1190-1 or LDDH1192-1 listed on the report.

In a further aspect of the invention an illustrative embodiment of aprocess used to recycle packing materials can be shown. Recipients canbe asked to voluntarily return package bags to CDC's 1190-1 forrecycling. Referring to FIG. 6, recipients can place empty package bags,including the package ties and packing sheets that came with eachpackage bag, in a package bag recycling chute (138) at a CDC 1190-1.Returned package bags can be left to accumulate in a package bagrecycling collection tank (140) of a CDC 1190-1, until a large volume ofthem has accumulated. Periodically, large batches of returned packagebags can be taken from package bag collection tanks (140), in CDC's1190-1 that do not have a package bag recycling machine (142), andtransported to a CDC 1190-1 in the same local market that does have apackage bag recycling machine (142). A package bag recycling machine(142) can be located in at least one CDC 1190-1 within a local market.Workers at a CDC 1190-1, where package bags can be recycled, canseparate package ties from package bags, and load the package bags andpacking sheets into a package bag recycling machine (142). A package bagrecycling machine (142) can condense bubble wrap package bags andpacking sheets into blocks of recycled plastic source material which canbe used later to make new package bags and packing sheets.

CDC workers can break down the empty cargo cages, that were receivedinto a CDC 1190-1, for shipping, by unlatching enough of the cargo cagelinking clasps to fold the sides of the cargo cages, down on top of eachother, to create flat condensed cargo cage units. Tractor-trailers canbe used to transport condensed cargo cage units, package bag ties, andblocks of recycled plastic source material from a local market to itsRDC 1180-1. While package bags, packing sheets, and package bag ties canbe grouped together to one or a few CDC's in a local market before beingrecycled and shipped to a RDC, cargo cages can be transported directlyfrom CDC's 1190-1 and LDDH's 1192-1 to a RDC 1180-1. The package bagsused in traditional deliveries to customer-specified addresses fromLDDH's 1192-1 can be returned to a CDC 1190-1. With reference to FIG. 8,after blocks of recycled plastic source material, package bag ties, anddisassembled cargo cages arrive at a RDC 1180-1 on a tractor-trailer(200 & 202), the different materials can be unloaded from the trailer(202) onto the local market receiving dock conveyor (14) and movedthrough the RDC 1180-1. The packing materials can travel to the localmarket sort conveyor (24) along the same path as inbound cases fromretailers. From the local market sort conveyor (24), the blocks ofrecycled plastic source material can be moved to a bubble wrap bagproduction machine (58), which can be located adjacent to the localmarket sort conveyor (24). The recycled plastic source material can befed into the bubble wrap bag production machine (58) to make new bubblewrap package bags and bubble wrap packing sheets. Newly created packagebags can be packed into totes carrying a standard quantity. The totescan be labeled with a barcode containing a special Case Id that canidentify the tote as one containing packing materials. A PackingMaterials Supply Program (346) can be used to generate a Case record1208 and a case label for each tote. The Case Id of packing materialtotes (cases) can consist of, for example, the current RDC Id+a valuesuch as “pm”+the current date+a sequential seven digit number. Statuscan be set to a value such as “destination RDC”. SKU can be set to avalue corresponding to the type of packing material—large package bags,small package bags, package bag ties, or packing sheets. Quantity can beset to the standard quantity packed in each tote for either small orlarge package bags. Quantity can be set to a value such as “1” forpackage bag ties or packing sheets (the exact quantity of package bagties and packing sheets in a tote may not be tracked). ePD Retailer Idcan be set to a value such as “pack”. The Temperature Code can be set toa value such as “standard”. Other fields on the Case record 1208 canhave no value when the record 1208 is created. The totes containingpacking materials can be placed onto the local market sort conveyor(24). Although not absolute, cargo cages can be preferably not labeledor placed into totes.

RDC workers performing the local market sort 1118 and CDC sort 1120 canbe responsible for picking totes of packing materials, as well as itemSKU cases, for the packing stations (45) which they support. There canbe special Order Header 1200 and Order Detail records 1202 for packingmaterials that define the safety stock for each type of packingmaterial. There can be a separate set of Order Header 1200 and OrderDetail 1202 records for each type of packing material, for each CDC1190-1 or LDDH 1192-1. Each set of packing material Order Header 1200and Order Detail 1202 records can establish a continual request for asupply of a packing material to meet the predefined safety stock of thatpacking material. Safety stock levels can be defined for each CDC 1190-1or LDDH 1192-1 based for example, upon the number of packing stations(45) normally in use for that CDC 1190-1 or LDDH 1192-1. The safetystock level quantities required for each CDC 1190-1 or LDDH 1192-1 canbe adjustable through a menu option function of the CDC Sort Program(328). Package bag safety stock levels can be set, for example, torequire two totes of the standard quantity of each package bag size perpacking station (45)—one full tote quantity for working stock andanother one for safety stock. Package bag tie, packing sheet, and cargocage safety stock levels can be set relative to the number of packagebags or totes of package bags in package bag safety stock levels. Forexample, one tote of package bag ties can be required for every 20 totesof package bags, 1.5 totes of packing sheets can be required for eachtote of package bags, 2.5 cargo cages can be required for each tote ofsmall package bags, and 6 cargo cages can be required for each tote oflarge package bags. The Order Header records 1200 for packing materialscan be defined, for example, as follows: Order Id consists of RDC Id+avalue such as “pack”+CDC Id+a filler value such as “010101”+a 3 digitnumber representing the type of packing material; Status can be set to avalue such as “open”; Local Market Id can be set to the value associatedwith the current CDC Id; CDC Id can be set to the value of the currentCDC 1190-1 or LDDH 1192-1 related to a group of packing stations (45);Customer Id can be set to a value such as “packing-m”; ePD Retailer Idcan be set to a value such as “pack”; and all other fields can have novalue. Order Detail records 1202 for packing materials can be defined,for example, as follows: Order Id can be the same as the value on thecorresponding packing material Order Header record 1200; Status can beset to a value such as “destination RDC”; SKU can be set to the valuerepresenting the type of packing material (consistent with the SKUvalues used on Case records 1208 for each type of packing material);Quantity can be set to the safety stock value as previously described;Temperature Code can be set to a value such as “standard”; and all otherfields can have no value.

As packages are created by workers at packing stations (45), the PackageCreation Program (330) can decrement the Quantity on the packingmaterial Case record 1208 of the current CDC 1190-1 or LDDH 1192-1, forthe package bag size that was used in creating the package. The PackageCreation Program (330) can also increment the Quantity on the PackingMaterial Restocking Counter table 1262 for the records having a Typevalue such as “package bag tie” and “packing sheet” and a CDC Id valueequal the current packing station CDC Id, as each new package iscreated. The Packing Material Restocking Counter table 1262 can serve asa counter, relative to package bag consumption, which can be used todetermine when to decrement the Quantity of a packing material Caserecord 1208, of package bag ties or packing sheets, from one to zero.Since the exact counts of package bag ties and packing sheets are nottracked, when the Packing Material Restocking Counter record 1262,tracking either package bag ties or packing sheets for packing stations(45) of the current CDC 1190-1 or LDDH 1192-1, reaches a predefinedlevel, the Quantity of a packing material Case record 1208, having thecurrent packing station CDC Id and the SKU of the packing materialreaching the predefined level, can be decremented from one to zero. Thepredefined level can be based upon the ratio of the consumption of thatpacking material relative to the consumption of package bags. Since Caserecords 1208 are not used to track the supply of cargo cages, the CDCSort Program (328) can use the Packing Material Restocking Counter table1262 as the supply count of cargo cages for the packing stations of thecurrent CDC 1190-1 or LDDH 1192-1.

Unlike normal Order Detail records 1202, packing material Order Detailrecords 1202 are not updated as packing material items are picked fromtotes to create packages, so the safety stock demand, against which thepacking materials supply can be measured, can remain constant. As theQuantity on a packing material Case record 1208 for the packing stationsof the current CDC 1190-1 or LDDH 1192-1 decreases below the safetystock level defined on its Order Detail record 1202, the CDC SortProgram (328) and Local Market Sort Program (326) can indicate to pick atote of that packing material, when the case label of one of thosepacking material totes is scanned. The sorting programs (326 & 328) canalso display a restocking alert message on a program display monitor ofworkstations used by the workers performing the CDC sort 1120 and localmarket sort 1118 for the packing stations of the CDC 1190-1, LDDH1192-1, or the local market of the CDC 1190-1 or LDDH 1192-1 for whichthe packing material demand has been realized. As the Quantity of aPacking Material Restocking Counter record 1262 of the packing stationsof a CDC 1190-1 or LDDH 1192-1, having a Type value such as “cargocage”, decreases below the safety stock level defined on its OrderDetail record 1202, the sorting programs (326 & 328) can also displayrestocking alert messages on the appropriate workstation program displaymonitors. Upon seeing the restocking alert message, workers performingthe local market sort 1118 and CDC sort 1120 can pick cargo cages fromthe local market sort conveyor (24) and CDC sort conveyor (42)respectively, to meet the demand. Workers performing the CDC sort 1120can enter the picked quantity into the CDC Sort Program (328) on theirworkstation keyboards, updating the cargo cage supply on the PackingMaterial Restocking Counter table 1262. Workers performing the localmarket sort 1118 can pick cargo cages from the CDC sort conveyor (42). Acargo cage does not have to be scanned and an update does not have to bemade to the Packing Material Restocking Counter table 1262 as cargocages are picked from the local market sort conveyor (24) to a CDC sortconveyor (42).

Referring to FIG. 12, there is shown an exemplary SmartBin Unit (SBU)consisting of revolving bins and stationary bins that can be subsectionsof a physical bin structure which can be configurable, and which can bedivided into two or more subsections. A SmartBin Unit can include afront exterior panel 230, side exterior panels 232, revolving bin doors234, revolving bin door handles 236, stationary bin doors 238,stationary bin door handles 240, a scanner port 242, a keypad 244, adisplay screen 246 and an exterior wiring duct 248.

Each subsection of a physical bin structure can be referred to as a binand the physical bin structure can be referred to as a master bin. Thuswith reference to the Bin Inventory table 1300 of FIG. 10A, if a masterbin is divided into two or more bins, each subsection or bin can havethe same Master Bin Id for one of its data attributes. The bins can alsohave Configuration Codes and Bin Sizes that identify the manner in whichthey have been divided. A Configuration Code can numerically describewhich subsections comprise a bin, of the possible number of subsectionswithin a master bin. Each subsection of a revolving master bin can benumbered, for example, from left to right starting with a value such as“1”. Each subsection of a stationary master bin can be numbered fromleft to right starting with the number equal to the highest revolvingbin subsection number, plus one. A Configuration Code can, for example,consist of only the numbers of the master bin subsections that comprisethe bin, moving from left to right. The Bin Size of any revolving bincan be equal to the number of its subsections. For example, a bin with aConfiguration Code of “234” can have a Bin Size of “3”. The Bin Size ofany stationary bin can be equal to its number of subsections+the largestpossible Bin Size of a revolving bin. For example, if the largestpossible Bin Size of a revolving bin is “4”, a stationary bin with aConfiguration Code of “6” can have a Bin Size of “5”. Each bin within aCDC 1190-1 can be tracked on the Bin Inventory table 1300 in thedatabase of that CDC's 1190-1 processing server. The Bin Inventoryrecord 1300 of each bin can contain a unique Bin Id, which can bederived by concatenating, for example, its SBU Id+its Master Bin Id+itsConfiguration Code.

The following two illustrative examples can illustrate how differentconfigurations of a master bin can be tracked on the Bin Inventory table1300. In the first illustrative example, a revolving master bin—MasterBin Id “02” of SBU Id “A01”—can be divided into three bins. Bin Id“A01-02-0012” can encompass the left half of the master bin and can havea Bin Size of “2”. Bin Id “A01-02-0003” can encompass the third quarterof the master bin, just to the right of Bin Id “A01-02-0012”, and canhave a Bin Size of “1”. Bin Id “A01-02-0004” can encompass theright-most quarter of the master bin and can have a Bin Size of “1”. TheConfiguration Codes of the three bins respectively can be as follows:“12”, “3”, “4”. In the second illustrative example, a stationary masterbin—Master Bin Id “S1” of SBU Id “A01”—can be configured as one bin,consisting of both master bin subsections. Bin Id “A01-S1-0056” canencompass the whole stationary bin, can have a Bin Size of “6”, and aConfiguration Code of “56”.

SBU master bins can have one or more two-section panels, calledconfiguration dividing panels (CDP's), hinged on one side to the topsurface of their bottom panels. Each CDP can be locked into one of twodifferent positions. For example, a consolidating position or thedividing position. The two sections of the CDP can be attached to eachother by folding hinges. The section which is not hinged to the bottompanel of the master bin can have, for example, four CDP cam locks, eachof which slide a CDP bolt 90 degrees to lock or unlock the CDP into oneof its two positions. CDC workers can use, for example, configurationkeys to lock a CDP into or unlock a CDP out of the dividing position orthe consolidating position. The CDP cam lock and configuration key canbe similar to the lock and key mechanism used to open and close vendingmachines. Configuration keys can be constructed in such a manner as tobe used interchangeably between all CDP cam locks and bin door cam locksof any SBU. The design of the configuration key can allow a worker witha key to make bin configuration adjustments to any SBU, while preventingsomeone without a configuration key from changing a bin's configuration,even if the door of the bin has been opened.

When a CDP is in the consolidating position, a first panel section ofthe CDP, which is hinged to the bottom of the master bin, can resthorizontally in a recessed area on top of the master bin's bottom panel.The second panel section of the CDP can rest horizontally on top of thefirst panel section, and can also be recessed so that the top surface ofthe second panel section is level with the surface of the rest of themaster bin's bottom panel. The CDP bolts of the four CDP cam locks canbe locked into locking slots, built into the sides forming the recessedarea within the master bin's bottom panel. When a CDP is in the dividingposition, the two panel sections of the CDP can both be vertical,sitting on top of each other, with the first panel section perpendicularto the bottom panel, of the master bin to which it is attached, and thesecond panel section perpendicular to the top panel of the master bin,into which it can be locked in place by two of its CDP bolts. Two of thesecond panel's CDP bolts can lock into locking slots in the top panel ofthe master bin, while the two CDP bolts on its other side can lock intolocking slots built into the side of the first panel section. The CDPbolts which can lock down into the side of the first panel section canprovide structural support to form a single, solid dividing panel. TheCDP bolts which can lock into the top panel of the master bin and thehinges which can attach the first panel section to the bottom panel ofthe master bin can secure the CDP as the side wall between two adjacentbins of a master bin.

If bin configurations are required to receive a delivery shipment, CDCworkers covering a CDC 1190-1 can be alerted that a ConfigurationAdjustments Report is printing on the CDC printer, while bins in thatCDC 1190-1 are being reserved for the delivery shipment. Upon arrivingat the CDC 1190-1 where the Configuration Adjustments Report printed,CDC workers can use the report to make the necessary configurationadjustments, step 1140, before the delivery shipment which triggered thereport is received. The Configuration Adjustments Report can guide a CDCworker to the SBU's, upon which the worker will make configurationadjustments, by listing them in SBU Id order. A CDC worker can, forexample, wear a hands-free barcode scanning device as the worker takesthe report to each listed SBU. The CDC worker can, for example, connectthe scanning device into the scanner port (242) of the first SBU listedon the report, scan their employee id card to identify themselves as theworker configuring the current SBU, and scan the first barcode next to aMaster Bin Id, listed underneath the SBU Id on the report. The scannercould also be a wireless scanner, which can communicate to a remotedevice or server. A SBU Configuration Program (352) of the ePD SBUApplication can be initiated on the CDC's 1190-1 processing server.Under each SBU Id on the Configuration Adjustments Report, Master BinId's can be listed in ascending order, with stationary master binspreceding revolving master bins. In one embodiment of a SBU, the SBU canhave only one stationary master bin, which can contain only one CDP, butbecause other embodiments may feature more than one stationary masterbin and/or may feature stationary master bins with more than one CDP, inthis disclosure both stationary master bins and their CDP's will bereferred to in a more general plural sense, rather than as one specificmaster bin or CDP. If more than one bin configuration adjustment is tobe made to one master bin, each bin configuration adjustment can belisted separately. For example, the Master Bin Id can be listed morethan once under its SBU Id. The new Configuration Codes of the bins tobe created within the master bin can be listed next to each Master BinId on the report, along with a barcode that can be used to trigger thedatabase changes associated with the configuration action.

There can be many possibilities of forming a new bin configuration froman existing one, but no matter what the bin configuration is at thestart and end of a bin configuration adjustment, every bin configurationadjustment can be classified as either a dividing bin configurationadjustment or a consolidating bin configuration adjustment. The barcodeof a dividing bin configuration adjustment can contain, for example, aconfiguration type identifier, followed by the Bin Id of the bin to bedivided, followed by the Configuration Code of each bin resulting fromthe bin configuration adjustment, in a barcode format which can beparseable. When the barcode of a dividing bin configuration adjustmentis scanned, the SBU Configuration Program (352) can parse the data inthe barcode, use the configuration type identifier to determine that theconfiguration action is a dividing one, and use the Bin Id to select theBin Inventory record 1300 of the bin being divided. The program (352)can create two or more new Bin Inventory records 1300 from the selectedBin Inventory record 1300, before deleting the selected record 1300.Each new Bin Inventory record 1300 can have the same values as thedeleted Bin Inventory record 1300, except for the Configuration Code,Bin Id, and Bin Size fields. The Configuration Code on the first record1300 created can be set to the value of the first Configuration Code,listed after the Bin Id, in the scanned report barcode. TheConfiguration Code on subsequently created records 1300 can be set tothe value of each subsequent Configuration Code, listed after the firstone, in the scanned report barcode. The Bin Id on each new record 1300can be derived, for example, by concatenating SBU Id+Master BinId+Configuration Code. Bin Size on new records 1300 created forrevolving bins can be set to the number of digits in the ConfigurationCode. Bin Size on new records 1300 created for stationary bins can beset to the number of digits in the Configuration Code added to the valueof the largest possible revolving Bin Size. The parseable barcode of aconsolidating bin configuration adjustment can contain, for example, aconfiguration type identifier, followed by the Configuration Code of thenew bin resulting from the bin configuration adjustment, followed by theBin Id of each bin within the master bin to be consolidated, in abarcode format. When the barcode of a consolidating bin configurationadjustment is scanned, the program (352) can parse the data in thebarcode, use the configuration type identifier to determine that theconfiguration action is a consolidating one, and use the Bin Id's toselect the Bin Inventory records 1300 of the bins being consolidated.The program (352) can create one new Bin Inventory record 1300 from theselected Bin Inventory records 1300, before deleting the selectedrecords 1300. The new Bin Inventory record 1300 can have the same valuesas the deleted Bin Inventory records 1300, except for the ConfigurationCode, Bin Id, Bin Size, and Status fields. The Configuration Code on thenew record 1300 can be set to the value of the Configuration Code,listed after the configuration type identifier, in the scanned reportbarcode. The Bin Id on the new record 1300 can be derived, for example,by concatenating SBU Id+Master Bin Id+Configuration Code. Bin Size onthe new record 1300 can be set for a revolving or stationary bin basedon the Configuration Code in a manner that can be consistent with theway it can be set for a dividing bin configuration adjustment. Statuscan be set to a value such as “available”.

As each dividing bin configuration adjustment is made to the BinInventory table 1300, the program (352) can update the Pending BinConfiguration Adjustments table 1304 to offset the amount of pending binconfiguration adjustments by the amount of bin configuration adjustmentsactually made. It can reduce the Quantity of the Pending BinConfiguration Adjustments record 1304, having the Bin Size andTemperature Code of the newly created Bin Inventory records 1300, by thenumber of new bins created. It can increase the Quantity of the PendingBin Configuration Adjustments record 1304, having the Bin Size andTemperature Code of the deleted Bin Inventory records 1300, by thenumber of records deleted. The Pending Bin Configuration Adjustmentstable 1304 does not have to be updated as consolidating binconfiguration adjustments are made, because pending consolidating binconfiguration adjustments can be tracked by the Status on specific BinInventory records 1300, instead of on Pending Bin ConfigurationAdjustments records 1304. With reference to FIG. 10B, the program (352)can also add a new record to a Configuration Adjustment Log table 1306to track each bin configuration adjustment made, using the data from thescanned report barcode and the scanned employee id. A ConfigurationAdjustment Id can be derived, for example, by concatenating the value ofthe first Bin Id listed in the scanned report barcode+the current date.Configuration Type can be set to the value of the configuration typeidentifier. The value of Bin Id 1 through Bin Id 4 can be set to thevalue of each Bin Id listed in the barcode, in the sequence that it islisted. The value of Configuration Code 1 through Configuration Code 4can be set to the value of each Configuration Code listed in thebarcode, in the sequence that it is listed. Employee Id can be set tothe value on the scanned employee id card, and Configuration Date/Timecan be set to the current date/time.

When the barcode of a stationary master bin listed on a ConfigurationAdjustments Report is scanned, the program (352) can unlock the bindoors (238) of the stationary master bin and display the Master Bin Idand the desired Configuration Codes on the SBU display screen (246). Theprogram (352) can separate the Master Bin Id and each individualConfiguration Code with, for example, hyphens, when displaying them on aSBU display screen (246). The worker can hold the stationary bin doors(238) open while using a configuration key to reposition the CDP's ofthe stationary master bin to achieve the bin configuration dictated bythe Configuration Codes listed on the Configuration Adjustments Reportand the SBU display screen (246). The worker can also use aconfiguration key to reposition bin door configuration bolts into eithera dividing or consolidating position to align the configuration of thestationary bin doors (238) with the new bin configuration. Unlike bindoor configuration bolts on revolving bin doors (234), which can bemoved electronically by ePD SBU Application programs, bin doorconfiguration bolts on a stationary bin door (238) can be moved manuallyusing a bin door cam lock, located near the bottom of the inside of astationary bin door (238). When a CDP has been moved in place to dividea stationary bin, the bin door configuration bolt between the two bindoors (238) on either side of that CDP should be in the dividingposition—for example, vertical, completely within the structure of oneof the two stationary bin doors (238). When a stationary bin CDP isfolded down and locked into the consolidation position, the bin doorconfiguration bolt, between the two stationary bin doors (238) on eitherside of where that CDP is hinged, should be in the consolidatingposition—for example, horizontal, overlapping into the locking slotwithin the structure of the stationary bin door (238) adjacent to thestationary bin door (238) into which it is built.

With reference to FIG. 10C, when the barcode of the first revolvingmaster bin of a SBU listed on a Configuration Adjustments Report isscanned, the program (352) can move the master bin of the scanned reportbarcode into the unloading position (the unloading/loading position of aSBU bin or master bin can be with the open front side of the master binlined up with the SBU's revolving bin doors (234)), move the bin doorconfiguration bolts to consolidate the revolving bin doors (234) to formone solid bin door across the entire revolving master bin, update thevalues on a SBU Settings record 1314 of the current SBU, and unlock therevolving bin doors (234). The SBU Configuration Program (352) can callor cause to be called, a Bin Positioning Program (372) and can useprogram logic similar to an Unloading Program (370) to position andunlock revolving bins. A difference between how the SBU ConfigurationProgram (352) works as compared to the Unloading Program (370) can be inhow it determines which bins to move and unlock. The SBU ConfigurationProgram (352) can determine which bins to move from the Master Bin Idassociated with one or more of the Bin Id's in the scanned reportbarcode, and it can unlock all the revolving bin doors (234). TheUnloading Program (370) can determine which bin to move and whichrevolving bin doors (234) to unlock from the information entered on theSBU keypad (244) by the package recipient. After moving the master bininto the unloading position and unlocking the revolving bin doors (234),the SBU Configuration Program (352) can display the Master Bin Id andthe desired Configuration Codes on the SBU display screen (246). Theworker can open the consolidated bin doors (234), lift them up againstthe front panel (230) of the SBU, and use a configuration key to lockthem into an open position. The locking bolt of a revolving bin door camlock, which can be located on the inside of one of the revolving bindoors (234), can slide into a locking slot on the front panel of the SBUto lock the bin doors (234) into an open position. The worker can use aconfiguration key to reposition the CDP's of the revolving master bin toachieve the bin configuration dictated by the Configuration Codes listedon the Configuration Adjustments Report and the SBU display screen(246).

Like the Unloading Program (370), whenever the SBU Configuration Program(352) moves the revolving bins and the revolving bin door configurationbolts, it can update the current SBU's record on the SBU Settings table1314 to account for the movements. It can set Load Position Master BinId to the Master Bin Id of the bin moved to the unloading position andDoor Configuration Code to the value that describes the current settingof each revolving bin door configuration bolt. The Door ConfigurationCode can be an alphanumeric value, consisting of zeros and ones. It canhave as many characters as there can be bin door configuration bolts,and each character can represent a bin door configuration bolt startingfrom left to right. Zeros can be used, for example, to denote that a bindoor configuration bolt is in the dividing position. Ones can be used,for example, to denote that a bin door configuration bolt is in theconsolidating position.

The worker can continue to scan the barcodes underneath the SBU Id onthe report and make the bin configuration adjustments to each master binas directed on the Configuration Adjustments Report and the SBU displayscreen (246). The SBU Configuration Program (352) can move a SBU's binsregardless of whether the revolving bin doors (234) of that SBU areclosed. After all bin configuration adjustment changes for a SBU arecomplete, the worker can, for example, scan a confirmation barcode,which can be listed on the last report line underneath the SBU Id, toconfirm that all the bin configuration adjustments listed for that SBUhave been made. Upon receiving a confirmation tone and a confirmationmessage on the SBU display screen (246) for example, the worker can usea configuration key to unlock the revolving bin doors (234) from theopen position. The worker can then lock the revolving bin doors (234) byfirmly pushing them closed. The worker can then proceed to the other SBUId's listed on the Configuration Adjustments Report, scanning theiremployee id card and making bin configuration adjustments on each oneuntil the end of the report is reached. After all the bin configurationadjustments listed on the Configuration Adjustments Report have beenmade and confirmed, the SBU Configuration Program (352) can end.

The Configuration Adjustments Report for one delivery shipment may besplit between two or more CDC workers making the bin configurationadjustments. Each worker can scan their employee id card before startingto make configurations to a SBU, allowing the program (352) to track theworker who made each bin configuration adjustment on the ConfigurationAdjustment Log table 1306.

In a further aspect of the invention, the tractor-trailer driver canstop at the CDC's 1190-1 and/or LDDH's 1192-1 listed on their DeliveryShipments Report in the sequence in which they can be listed. Prior toarriving at the CDC's 1190-1, the driver can use a communication meanssuch as a cellular phone to call a Primary Contact Number for each CDC1190-1 in order to alert CDC workers that a delivery shipment willarrive, give, for example, an estimated time of arrival, and let theworkers know whether the incoming delivery shipment encompasses more orless than half of the trailer (202). If the attempt to reach the team ofCDC workers covering the CDC 1190-1 using its Primary Contact Numberfails, the driver can attempt to call the CDC's 1190-1 Secondary ContactNumber (both numbers can be listed on the Delivery Shipments Report witheach CDC Id). In one embodiment, the Primary Contact Number andSecondary Contact Number of a CDC 1190-1 do not dial telephones locatedin the CDC facility 1190-1. Instead, the contact numbers can dialcellular phones designated to those CDC's 1190-1. As a team of CDCworkers begins its work shift to cover a group of CDC's 1190-1, the CDCworkers of the prior work shift can transfer the cellular phones,designated to the CDC's 1190-1 they are covering, to the team of CDCworkers accepting coverage responsibility for those CDC's 1190-1.Depending upon the designation of the CDC coverage routes within a localmarket, there can be a group of CDC's 1190-1 which share the samecontact numbers. Upon receiving a call from a tractor-trailer driver,the team of CDC workers can travel to the identified CDC 1190-1 to meetthe delivery shipment. In one embodiment, a tractor-trailer driver doesnot need to call ahead to alert a LDDH 1192-1 when making a deliverythere, as LDDH's can have dedicated workers on site to receive deliveryshipments.

The CDC workers can arrive ahead of the delivery shipment in order tominimize the time (and the costs associated with that time) thetractor-trailer and its driver spend away from their primary function oftransporting cases and packages. With reference to FIG. 6, prior to thearrival of the delivery shipment, CDC workers can position a number ofmobile putaway conveyor units (143) on the receiving dock area, in frontof the CDC receiving dock conveyor extension (145). In one embodiment,either four or eight mobile putaway conveyor units (143) can be useddepending upon the size of the delivery shipment. Eight conveyor units(143) can be set up, if the driver indicated that the delivery shipmentfor the CDC 1190-1 encompassed more than half of the trailer. Fourconveyor units (143) can be set up, if the driver indicated that thedelivery shipment encompassed less than half of the trailer. Some of theconveyor units (143) may have already been positioned and prepared toreceive the next delivery shipment by the CDC workers who last usedthem. Although specified units can be described, other quantities can beused without departing from the spirit of the invention.

For illustration, each mobile putaway conveyor unit (143) can have anelectric power outlet on the side of its base component, below arotating conveyor component, above where wheels can be attached to thebase, at each of the corners of the base component. Each conveyor unit(143) can be as wide as half the width and as long as one-fourth of thelength of a trailer conveyor (204). When positioning the conveyor units(143), the workers can connect power cables between the power outlets ofadjacent conveyor units (143), forming a horseshoe shaped chain, forexample, starting from the front-left unit. The power cable connectionsbetween the conveyor units (143) can extend back the left side to theunit farthest away from the CDC delivery dock door (144), across to aback-right unit, and back up the right side to the unit positioned tothe right of the front-left unit. The power cables used to connect theunits (143) to each other can normally sit with one end plugged into oneof the power outlets of the unit (143), and the other plug end, forexample, fastened under a holding clip built into the side of that unit(143). The power cable at the front-left corner of the front-left unit(143), can be plugged into an electrical power outlet, located forexample, on the base of the CDC receiving dock conveyor extension (145),underneath its pivoting conveyor component. Since the CDC receiving dockconveyor extension (145) can be plugged into an electric power outlet ofthe CDC facility 1190-1, electric power can be supplied to each of themobile putaway conveyor units (143) linked together by the power cables.Another step in positioning conveyor units (143) to receive a deliveryshipment can be locking their wheels to prevent the conveyor units (143)from moving, as cargo cages get loaded onto them. Each mobile putawayconveyor unit (143) can have a wheel locking mechanism that can be setto either lock all of its wheels or allow them to move freely. CDCworkers can engage the wheel locking mechanism on each conveyor unit(143) after that conveyor unit (143) has been aligned in position toreceive a delivery shipment. Yet another step in preparing the conveyorunits (143) to receive a delivery shipment can be to raise a cargo stopwall on the two units farthest from the CDC delivery dock door (144), toprevent cargo cages from moving off of the end of the conveyor unit(143) as they are loaded onto the conveyor units (143). Cargo stop wallscan be slightly less than the width and height of the backside of thebase of the conveyor unit (143) into which they can be built. Cargo stopwalls can be contained within a rectangular frame that can be built intothe backside of the base of the conveyor unit (143) just beyond the edgeof the end of the conveyor component. The cargo stop walls can bepositioned either in the inactive position—down inside its base frame—orin the active position—extended upward from the top of the frame,forming a wall that extends beyond the top of the conveyor component. Aspring-loaded locking pin can be used to keep a cargo stop wall in oneof the two positions and must be disengaged to allow the cargo stop wallto be moved from one position to the other. The mobile putaway conveyorunits (143) can be designed to be interchangeable with each other. Thatcan simplify the steps involved in positioning them by removing thepossibility of positioning one in the wrong place. The conveyor units(143) do need to be positioned in the correct direction, however, toenable the movement of their conveyors to be in synchronization witheach other, the dock conveyor extension (145), and the trailer conveyor(204). A correctly positioned conveyor unit (143) can have its cargostop wall end away from the CDC delivery dock door (144). After themobile putaway conveyor units (143) are positioned and ready to receivea delivery shipment, one of the CDC workers can open the CDC deliverydock door (144). The CDC workers can then await the arrival of thetractor-trailer (200 & 202) carrying the delivery shipment.

In step 1142, a delivery shipment can be received into a CDC 1190-1.When the tractor-trailer (200 & 202) arrives and finishes backing up tothe CDC delivery dock door (144), a CDC worker can open the door of thetrailer and lower the CDC receiving dock conveyor extension (145) to thehorizontal unloading position. The lowered conveyor extension (145) canbridge the gap between the trailer conveyor (204) and the mobile putawayconveyor units (143) to form one continuous set of conveyor sections.One of the CDC workers can switch on the conveyors of the mobile putawayconveyor units (143) and the CDC receiving dock conveyor extension (145)to move in the unloading direction (away from the trailer (202)). A CDCworker can then switch the trailer conveyor (204) to move in theunloading direction (toward the trailer door) and the cargo cages andsingle-item packages can be moved from the trailer conveyor (204) acrossthe conveyor extension (145), and on to the conveyor units (143). If thedriver had informed the CDC workers that the delivery shipmentencompassed less than half of the trailer (202), for example, only fourconveyor units (143) would be positioned to receive the deliveryshipment, and the trailer conveyor (204), conveyor extension (145), andconveyor units (143) can be stopped after a delivery shipment the sizeof approximately half of the contents of the trailer is moved onto theconveyor units (143). If the driver had informed the CDC workers thatthe delivery shipment encompassed more than half of the trailer (202),for example, eight conveyor units (143) would be positioned to receivethe delivery shipment, and the trailer conveyor (204), conveyorextension (145), and conveyor units (143) can be stopped after adelivery shipment the size of approximately all of the contents of thetrailer (202) is moved onto the conveyor units (143). While the numberand the design of conveyor units (143) required can be specified, othernumbers of conveyor units (143) and variations in the design of thoseconveyor units (143) can appropriately be used without departing fromthe spirit of the invention. The cargo cages and single-item packages atthe leading end of the delivery shipment can move across the conveyorunits (143) closest to the trailer (202), and then back onto the onesfarthest away from the trailer (202), until they hit up against thecargo stop walls at the back end of the conveyor units (143) farthestaway from the trailer (202).

The CDC workers can look at the delivery shipment label plate on one ofthe first cargo cages at the lead end of the delivery shipment toconfirm that the delivery shipment unloaded is for the current CDC1190-1. They can then work their way back looking for another deliveryshipment label plate on the other cargo cages to determine where thecurrent CDC's 1190-1 delivery shipment ends and another CDC's 1190-1delivery shipment begins. If the contents of the trailer (202) containsmore than one delivery shipment, the workers can see a delivery shipmentlabel plate with a different CDC Id listed on it, marking the cut offpoint between two different delivery shipments. If the CDC workers dofind a second delivery shipment label plate, they can switch the trailerconveyor (204), the conveyor extension (145), and the conveyor units(143) in the loading direction to move the cargo cages and single-itempackages of the second delivery shipment back onto the trailer conveyor(204). If necessary, the appropriate sections of the coordinated systemof conveyors—trailer conveyor (204), CDC receiving dock conveyorextension (145), and mobile putaway conveyor units (143)—can becontrolled separately from each other in a coordinated manner to movecargo cages and single-item packages back onto the trailer (202). Oncethe delivery shipment for the current CDC 1190-1 has been unloaded ontothe conveyor units (143) and any parts of other delivery shipments,which may have been partially unloaded, have been reloaded back onto thetrailer conveyor (204), the different components of the coordinatedsystem of conveyors can be switched off. A CDC worker can, for example,manually move the conveyor extension (145) into the vertical non-loadingposition, close the trailer door, and close the CDC delivery dock door(144).

The driver of the tractor-trailer can give one of the CDC workers theDelivery Shipments Report for the current CDC 1190-1. In one embodiment,the CDC worker can connect a hands-free barcode scanning device to aworkstation running the current CDC's 1190-1 instance of the ePD SBUApplication. The worker can, for example, initiate a Loading GuideReport Program (354) to run on the workstation and use the hands-freebarcode scanning device to scan their employee id card and the reportbarcode underneath the current CDC 1190-1 on the Delivery ShipmentsReport to accept the delivery shipment. The Loading Guide Report Program(354) can read the report barcode and parse the information it containsaccording to its standard format. The barcode on the Delivery ShipmentsReport can contain the Delivery Shipment Id, the Temperature Code, andthe number of packages in the delivery shipment of each Package Size.

The number of packages of each size can be listed in the barcode, inincreasing Package Size sequence, using a standard number of digits perPackage Size. Due to the nature of how packages can be transported,packages received in the same delivery shipment can have the sameTemperature Code. Packages having a Temperature Code value such as“refrigerated” or “freezer” can arrive in temperature-controlledvehicles that can maintain the temperature conditions required by eachof those types of packages, while packages having a Temperature Codevalue such as “standard” can arrive in non-temperature controlledtractor-trailers. The Loading Guide Report Program (354) can search theBin Inventory table 1300 for the count of records of each Bin Sizehaving the Temperature Code of the delivery shipment and a Status suchas “available”, and can compare that count of available bins against thepackage counts of each corresponding Package Size from the DeliveryShipments Report barcode to create a Loading Guide Report. The LoadingGuide Report Program (354) can read a High-Availability Bins data view1307 before searching the Bin Inventory table 1300, so that it cansearch the Bin Inventory table 1300 for SBU's having a large number ofavailable bins, first, before searching for other SBU's having lessavailability. Both data sets (SBU Id's with high availability and otherSBU Id's) can be selected in SBU Id sequence. The ePD SBU Applicationcan maintain the High-Availability Bins data view 1307 dynamically asthe underlying Bin Inventory table 1300 is updated. TheHigh-Availability Bins data view 1307 can list, for example, the SBU Id,Temperature Code, and Available Quantity of bins for SBU's which have aquantity of available bins greater than a target number considered toindicate high availability (such as more than 50% of its bins areavailable). The setting for the number or percentage of bins availableto be considered as indicating a high availability can be configurableand can be set differently at each CDC 1190-1. As the Loading GuideReport Program (354) creates the Loading Guide Report, it can save thelisting of SBU Id's needed to accept the packages of the smallestPackage Size. In searching for SBU Id's to accept packages of eachincreasing Package Size, the Loading Guide Report Program (354) cansearch the saved list of SBU Id's first, before searching selected SBUId's with high bin availability, and then searching other SBU Id's. SBUId's can be added to the list being saved for the report, during thesearch for bins of each Package Size, if the search for that PackageSize is not satisfied by the existing saved list. The program (354) canprint the Loading Guide Report as the final saved list of SBU Id's, inSBU Id sequence, once the program (354) has finished its search for allPackage Sizes of the delivery shipment. The Loading Guide Report canlist, for example, the total quantity of available bins of each Bin Sizefor each SBU Id that it lists.

In addition to printing the Loading Guide Report, the Loading GuideReport Program (354), can for example, open a remote dial-up connectionwith the RDC server, of the destination RDC 1180-1 serving the currentCDC 1190-1, and update the Delivery Shipment table 1238 of the ePDDelivery Application. The following updates can be made to the DeliveryShipment record 1238 having the Delivery Shipment Id of the scannedreport barcode: Status can be set to a value such as “received”;Delivery Shipment Arrival Date/Time can be set to the current date/time;and CDC Employee Id can be set to the value of the scanned employee idcard. The update to the Status of the Delivery Shipment record 1238 bythe ePD SBU Application can trigger, or cause to be triggered, the ePDDelivery Application, which can be running on the RDC server, toautomatically update the Status to a value such as “in CDC” on allPackage table records 1234 having a Delivery Shipment Id equal to thevalue in the updated Delivery Shipment record 1238. As the ePD DeliveryApplication updates the Status on each Package record 1234, it can alsoupdate the Order Detail records 1202 that contain that Package Id,setting their Status to a value such as “in CDC”.

After scanning the barcode on the Delivery Shipments Report, the CDCworker can hand the report back to the driver and the driver can departfor the next CDC 1190-1 listed on the report. CDC workers can disconnectthe power cables between the mobile putaway conveyor units (143), unlockthe wheels of the conveyor units (143), and move the conveyor units(143) into a holding cage (134) designated to the shipping organizationfor which they work. With reference to FIG. 6, a holding cage (134) canbe an area within the backroom area (154) of a CDC 1190-1, which can besecured by a fence-like structure, which can have a lockable door. TheCDC workers can lock the holding cage (134) and travel to the next CDC1190-1 listed on the Delivery Shipments Report to meet thetractor-trailer driver. The CDC workers can continue to unload thetrailer (202) until it becomes empty or contains only delivery shipmentsfor LDDH's 1192-1. When the workers get finished unloading the trailer's(202) last CDC delivery shipment, the CDC workers can begin to load thepackages of the delivery shipment into SBU's in whichever CDC 1190-1they are currently in. After disconnecting the power cables andunlocking the wheels of the conveyor units (143), the CDC workers canbegin to move the conveyor units (143) throughout the CDC 1190-1 to loadthe packages of the delivery shipment into SmartBin Units (SBU's) (158),as illustrated in step 1144. The workers can then travel back to theother CDC's 1190-1 in which they received a delivery shipment to loadthe packages of the delivery shipments, which they had previously placedinto the holding cages (134). In one embodiment, multiple shippers candeliver to the same CDC's 1190-1, and different holding cages (134) cancorrespond to different shippers and can have security to restrictaccess to only workers of that shipper. In another embodiment, an entireCDC 1190-1 can be run by one shipper and mobile putaway conveyor units(143) can be left in the back room area (154) of the CDC 1190-1,eliminating the need for holding cages (134). In either embodiment, theentire back room area (154) of a CDC 1190-1 can be secured to allowaccess to shipper workers only.

After a driver unloads all of their delivery shipments, the driver canleave for a retailer site or can load up CDC reverse shipments and/orrecycled materials depending upon their next scheduled run. At thispoint in the ePD Delivery Process, the packages of a delivery shipmenthave been delivered in bulk and received into a CDC location 1190-1 asillustrated in step 1142. The bulk delivered packages of the deliveryshipment can later be retrieved by many different recipients, in step1150.

Following step 1142, the packages can be loaded into the SBU's (158) asillustrated in step 1144 of FIG. 1. After the CDC workers unload thelast delivery shipment from a trailer into a CDC 1190-1, they can usethe Loading Guide Report to guide them as they move mobile putawayconveyor units (143) from the CDC back room area (154) or holding cage(134) through the main room delivery entrance door (146), into the CDC'smain aisle (170), cross aisles (162), and side aisles (160) to the SBU's(158) listed on the report. To load the bulk delivered packages into aSBU (158), a CDC worker can connect, for example, a hands-free scanningdevice into a SBU's scanner port (242) and can scan, for example, theiremployee id card to activate the Loading Program (356) of the ePD SBUApplication. The Loading Program (356) can determine which revolvingmaster bin is closest to the loading position and has at least oneavailable bin, so that it can move that bin into the loading position.To select the closest bin with a Status value such as “available”, theLoading Program (356) can select the record from the SBU Settings table1314 having the SBU Id of the current SBU (158). With reference to FIG.10D, the Loading Program (356) can use, for example, the value in theLoad Position Master Bin Id field of the selected SBU Settings record1314, to select all the Master Bin After Movement values for that masterbin from a Master Bin by Movement table 1316. The Loading Program (356)can use each selected Master Bin After Movement value, in the sequencethe fields can be listed on the Master Bin by Movement table 1316 (whichcan be sequenced by the lowest absolute value of a movement), to searchthe Bin Inventory table 1300 for the first record having, for example,the current SBU Id, a Status value such as “available”, and a Master BinId value matching the selected Master Bin After Movement value. Thefirst Bin Inventory record 1300 it finds meeting that criteria cancontain the closest available bin. Once the Master Bin Id of the closestavailable bin is determined, the Loading Program (356) can call or causeto be called, a Bin Positioning Program (372) to determine the movementneeded to position the selected master bin into the loading position.The Loading Program (356) can pass the Load Position Master Bin Id valuefor the current SBU (158) and the Master Bin Id value of the selectedmaster bin (the one for the closest available bin) to the BinPositioning Program (372) as inputs. The Bin Positioning Program (372)can use the input values to search a Bin Movement table 1315 for themovement required to move the selected master bin into the loadingposition. The Loading Program (356) can send a motor command to the SBUmotor to move the revolving bins by the movement value returned from theBin Positioning Program (372). Upon receiving the motor command, the SBUmotor can move the revolving bins to position the selected master bininto the loading position.

The Loading Program (356) can read a Door Configuration Code value fromthe SBU Settings record 1314 it had selected for the current SBU (158)and can determine the bin door configuration commands needed to move thebin door configuration bolts to consolidate all the revolving bin doors(234) to form one solid bin door across the entire revolving master bin.The Loading Program (356) can send the needed bin door configurationcommands to the bin door configuration mechanisms on the revolving bindoors, and the bin door configuration bolts can be moved accordingly. Inreferring to sending a bin door configuration command to a bin doorconfiguration mechanism in this disclosure, a program can be sending thecommand directly to the bin door configuration mechanism through a localarea network connecting each SBU (158) to the CDC processing server orit can actually be sending the command to a bin door configuration boltcontroller, which in turn, can interpret the command and initiate theaction through a wired connection to the bin door configurationmechanism. If a bin door configuration bolt controller is used, it canbe centralized to control all the bin door configuration mechanisms in aCDC 1190-1 or specific to a single SBU (158) or a group of SBU's (158).The program (356) can update the values on the SBU Settings record 1314of the current SBU (158) to reflect the bin movement and the bin doorconfiguration bolt movement. The program (356) can send an unlockcommand to the bin door locking mechanism of each revolving bin door tounlock all of the revolving bin doors (234). In referring to sending anunlock command to a bin door locking mechanism in this disclosure, aprogram can be sending the command directly to the bin door lockingmechanism through a local area network connecting each SBU (158) to theCDC processing server or it can actually be sending the command to alock controller, which in turn, can interpret the command and initiatethe action through a wired connection to the bin door locking mechanism.If a lock controller is used, it can be centralized to control all thebin door locking mechanisms in a CDC 1190-1 or specific to a single SBU(158) or a group of SBU's (158). The program (356) can also send, forexample, a display command to display the Master Bin Id andConfiguration Codes of the master bin in the loading position, on theSBU display screen (246). The Loading Program (356) can also check theStatus of the Bin Inventory records 1300 for the current SBU's (158)stationary bins to determine if one or more of them have a Status suchas “available”. The Loading Program (356) can send an unlock command tothe bin door locking mechanism of one or more of the stationary bindoors, as needed, to unlock the bin doors (238) corresponding toavailable stationary bins.

A CDC worker can open consolidated revolving bin doors (234), lift themup against the front panel (230) of the SBU (158), and use aconfiguration key to lock them into the open position—fully open,against the SBU (158), above the bin door openings of the revolvingbins. The worker can pick a bulk delivered multi-item package from oneof the cargo cages on the mobile putaway conveyor unit (143), scan thebarcode on its package label, and place it into the left-most availablebin with the package tie handle facing out or to one side of the bin.The worker can then scan the bin door label barcode located on theinside of the bin door (234) of the bin in which the bulk deliveredmulti-item package was loaded. In one embodiment, if a bin is configuredto span across more than one revolving bin door (234), the bin doorlabel on the left-most bin door (234) corresponding to the bin must bescanned. The Loading Program (356) can, for example, sound an error toneand/or display an error message, if a bin door label other than theleft-most one of an available bin gets scanned, or if a bin door labelof a bin that already contains a package gets scanned, or if two packagelabels get scanned consecutively, or if two bin door labels get scannedconsecutively. When a loading error occurs, the program (356) can alsoclear its memory of a Package Id that may have been scanned in thetransaction prior to the error. If the bulk delivered package getsloaded successfully when a package label and then a bin door label arescanned, the Loading Program (356) can for example, sound a confirmationtone and/or display a message on the SBU's display screen (246),confirming that the package was loaded successfully.

As each bulk delivered package gets loaded into a SBU bin, the LoadingProgram (356) can update the Bin Inventory 1300 and Bin Reservationtables 1302 of the SBU Application, and can create a new record on aNotification Check table 1310 of the SBU Application. The LoadingProgram (356) can read, for example, a Customer Id, embedded in thePackage Id on the scanned package label, and can use it to select theCustomer table record 1256 corresponding to the bulk deliveredmulti-item package. The Loading Program (356) can use the Employee Id onthe scanned employee id card to select the ePD Shipper Id from theEmployee table 1308. The Loading Program (356) can read the SBU Id and aBin Door Identifier, in the barcode on the scanned bin door label, andcan use that SBU Id to search the SBU Settings table 1314 to determinewhich master bin is in the loading position. The Loading Program (356)can then select the Bin Inventory record 1300 of the bin in which thebulk delivered multi-item package was loaded, by selecting the BinInventory record 1300 having the SBU Id of the scanned bin door label, aMaster Bin Id equal to the value of the Load Position Master Bin Idfield on the SBU Settings record 1314 having that SBU Id, and aConfiguration Code that contains the Bin Door identifier of the scannedbin door label. The Loading Program (356) can update the selected BinInventory record 1300, for example: Package Id can be set to the valueof the barcode scanned on the package label; Customer Id can be set tothe Customer Id value embedded in the Package Id; PIN can be set to thevalue on the selected Customer record 1256; Status can be set to a valuesuch as “loaded”; Delivery Employee Id can be set to the value scannedfrom the barcode on the employee id card; ePD Shipper Id can be set tovalue from the selected Employee record 1308; and Delivery Date/Time canbe set to the current date/time. The Loading Program (356) can select,for example, the Bin Reservation record 1302 having the Bin Size,Temperature Code, and ePD Shipper Id of the Bin Inventory record 1300which it just updated and a Status such as “new”, and can decrement itsQuantity by one. If more than one Bin Reservation record 1302 getsselected using Bin Size, Temperature Code, and ePD Shipper Id, theLoading Program (356) can update the one with the earliest ReservationDate/Time. When the Quantity of a Bin Reservation record 1302 reacheszero, the Loading Program (356) can set its Status to a value such as“filled”. The Loading Program (356) can also create a new record on theNotification Check table 1310 by writing the Customer Id that wasembedded in the Package Id on the new record 1310.

If there is another available bin in the master bin in the loadingposition, after a bulk delivered multi-item package gets loaded, theworker is able to load another bulk delivered multi-item package usingthe same steps just described. When all the bins in the current masterbin are filled after a bulk delivered multi-item package is loaded, theLoading Program (356) can move the revolving bin structure to positionthe closest remaining master bin, having at least one available bin,into the loading position. The Loading Program (356) can, for example,repeat the processing performed to move the first closest available bininto the loading position, when determining the movement needed toposition the closest remaining available bin into the loading position.In one embodiment, the program commands are not issued to move bin doorconfiguration bolts or unlock revolving bin doors as the Loading Program(356) subsequently positions each master bin into the loading position,because the revolving bin doors (234) can already be locked into theopen position. The worker can continue to load bulk delivered multi-itempackages into available bins in this manner until the SBU (158) nolonger has any available revolving bins.

Workers can also load bulk delivered single-item packages into a SBU's(158) stationary bins by placing the bulk delivered single-item packagein the stationary bin, scanning its package label, and scanning the bindoor label of the bin. In one embodiment, stationary bin doors (238) arenot locked into or out of a loading position using a configuration key.When loading bulk delivered single-item packages into a stationary bin,a worker can hold the stationary bin doors (238) open while placing thepackage into the stationary bin. Unlike the loading of bulk deliveredmulti-item packages into revolving bins, the Loading Program (356) doesnot confirm the bulk delivered single-item package as being successfullyloaded into a stationary bin until its stationary bin door (238) getspushed closed to lock the stationary bin. After the program makes theupdates to the Bin Inventory 1300 and Bin Reservation 1302 records andcreates the new Notification Check record 1310 for the bulk deliveredsingle-item package (in the same manner as described forupdating/creating records when multi-item packages are loaded intorevolving bins), it can display a message to prompt the worker to closethe bin door, and it can check the state of the bin door sensor (of thebin in which the bulk delivered single-item package was loaded) todetermine if the bin door has been closed. The Loading Program (356)can, for example, sound an error tone and display an error message ifany scanning action is done before the bin door of the stationary bininto which the bulk delivered single-item package was loaded, has beenclosed. When that bin door (238) gets closed, the Loading Program (356)can, for example, sound a confirmation tone and display a confirmationmessage on the SBU display screen (246). Other audio, or visual alertsmay be utilized. A worker is not required to close the bin doors (238)of a stationary bin, unless a package has been loaded into thatstationary bin. A stationary bin can be allowed to remain empty as theprogram (356) ends.

When the Loading Program (356) unlocks bin doors (234 or 238) at itsstart, the bin doors (234 or 238) can be pushed out to rest upon lockingmechanisms, and the locking mechanisms can be set back into a lockedposition. The SBU bin door lock (for both revolving bins and stationarybins) can consist of, for example, three components: a two-pronged bindoor locking mechanism which can extend from the SBU frame, a catch slotin the bin door (234 or 238) into which the bin door locking mechanismcan fit to form the lock, and a spring-loaded bin door sensor which canextend outward from the SBU frame in its natural state when it is notcompressed. In one embodiment, the SBU bin door locks may only becapable of performing a minimal amount of functions: unlocking anddetecting if a bin door (234 or 238) is closed. In this embodiment, aclosed bin door can always be a locked bin door, and the lock movementswhich can be triggered by programs of the ePD SBU Application do notactually perform the locking function. A person applying pressure to thebin door (234 or 238) to close it can be the action that locks a bindoor (234 or 238). It should be noted while the embodiment of thelocking mechanism described can contain the specified components, othercombination of components can be possible without departing from thespirit of the invention.

When a SBU bin door (234 or 238) gets closed and locked, the prongs ofthe locking mechanism can fit inside the bin door catch slot and theheads of each prong can extend around the side edges of the catch slothooking it into a locked position. The spring action of the bin doorsensor can be constantly trying to extend outward into its naturaluncompressed position. Because the bin door sensor can be situatedbetween the bin door (234 or 238) and the SBU frame, when the bin doorsensor moves from a compressed state into its natural uncompressedstate, it can push the bin door (234 or 238) away from the SBU frame.The bin door locking mechanism prongs, when hooked around the side edgesof the catch slot, can prevent the bin door sensor from extending intoan uncompressed state, as they hold the bin door (234 or 238) into placeagainst the SBU frame, forcing the bin door sensor to be compressed.When the bin door lock receives an unlock command from the CDC server,it can contract the two prongs of the locking mechanism toward eachother, into an unlocked position, where the prong heads can becompletely within the catch slot, no longer extending beyond the catchslot's side edges. Since the prongs no longer remain in position tosecure the bin door (234 or 238), the spring action of the bin doorsensor can then extend away from the SBU frame pushing the bin door (234or 238) away from the SBU frame and beyond the front end of the prongheads. When the unlock command has finished contracting the prongs, theprongs can be released back into the locked position. Even though theprongs can be in the locked position, however, the bin door (234 or 238)can be unlocked because it can already have been pushed out beyond thefront edge of the prong heads and can be resting in an unclosed positionagainst the prongs and the bin door sensor. When a person appliespressure to push the bin door (234 or 238) closed, the catch slot of thebin door can push against the angled front edges of the prong heads,forcing them to contract in toward each other until they are narrowenough to fit inside the side edges of the catch slot. As the bin door(234 or 238) continues to move toward the SBU frame and the prong headshave passed completely inside the catch slot, the prong heads can extendoutward to their normal position hooking around the inside edges of thecatch slot in the locked position. The bin door sensor can becomecompressed as the bin door (234 or 238) is closed and can register aclosed status once the bin door (234 or 238) is flat against the SBUframe.

When there are no available revolving or stationary bins remaining in aSBU (158), the Loading Program (356) can, for example, sound a messagealert tone and display a message requesting the worker to close therevolving bin doors (234). The action of closing the revolving bin doors(234) of a SBU (158) while the Loading Program (356) is running for thatSBU (158), can end the Loading Program (356) for that SBU (158). A CDCworker can use a configuration key to unlock the revolving bin doors(234) from the open position, and the revolving bin doors (234) can fallagainst their corresponding bin door locking mechanisms. The worker canpush the revolving bin doors (234) firmly against their lockingmechanisms until they get locked into place. As the Loading Program(356) determines that all the revolving bin door sensors are in theclosed position, it can, for example, sound a confirmation tone, displaya confirmation message that the program has ended successfully, and end.A worker can then disconnect their hands-free scanning device or othersuitable scanning device from the SBU scanner port (242) and can proceedon to the next SBU (158) listed on the Loading Guide Report. If theworker did not close all of the revolving bin doors to end the program(356) successfully, the Loading Program (356) can, for example, sound anerror tone and display an error message, indicating that one of therevolving bin doors (234) has not been closed properly. In oneembodiment, this validation step can occur when that worker tries toscan their employee id card to log into another SBU (158). In anotherembodiment, a worker can scan a SBU Id barcode on a label affixed to theexterior of a SBU to switch from loading one SBU to another instead ofscanning an employee id card, and the Loading Program (356) can performthe validation step to ensure that all the revolving bin doors (234) ofa SBU (158) have been closed properly at the time the SBU Id barcode ofanother SBU (158) is scanned. CDC workers do not have to be restrictedto loading bulk delivered packages into SBU bins in any particularorder. Although a Loading Guide Report can be used as a guide to makethe package loading process more efficient by pointing workers towardthe SBU's (158) with the most available bins, CDC workers can loadpackages into any available SBU bin, whether or not it is listed on aLoading Guide Report.

SBU's (158) can be loaded in the same manner regardless of where theycan be located in a CDC 1190-1. Some SBU's (168 and 188 respectively)can be located in refrigerated or freezing temperature controlled areaswithin the CDC 1190-1. Others can be located outside the air-conditionedspace of a CDC facility 1190-1, for example, on trailers or undercovered areas in a CDC's parking lot. The practice of using SBU's (158)outside of a CDC 1190-1 in a temporary fashion can be employed toprovide additional bin capacity to accommodate extremely high seasonalvolumes of packages delivered in bulk.

After the team of CDC workers finishes loading all the bulk deliveredpackages of a delivery shipment in one CDC 1190-1, the team can travelto another CDC 1190-1 where a delivery shipment was received, to loadthe packages of that delivery shipment. Optionally, a program can beused to create an exception report that can compare the Package Id'shaving a particular Delivery Shipment Id (the bulk delivered packages ina particular delivery shipment) against the Package Id's on the BinInventory table 1300 of the CDC 1190-1 having the CDC Id embedded withinthat Delivery Shipment Id (the bulk delivered packages that have beenloaded into bins at the CDC 1190-1 where that delivery shipment wasdelivered). This exception report can be created at either the CDC1190-1 by a CDC worker before leaving for another CDC 11901 or by a RDCworker at the destination RDC 1180-1 from which the delivery shipmentwas sent. The exception report can be used to help ensure that the bulkdelivered packages of a delivery shipment are accounted for and toidentify and investigate packages that are shipped from a destinationRDC 1180-1 but not loaded into a SBU (158).

Following the loading of bulk delivered packages into SBU's (158) asdescribed in step 1144, notification contacts can be made according tostep 1148. Recipients can receive electronic notification messages toalert them that bulk delivered packages have been delivered to a CDC1190-1 for them. The electronic notification can be an automated messagedelivered by a telephone call, e-mail, facsimile machine, or analphanumeric pager. Several programs and tables can be employed by theePD Delivery Process to provide flexibility in the method and timing ofsending electronic notification messages to recipients to alert orremind them that they have one or more bulk delivered packages ready tobe picked up from a CDC 1190-1. Recipients can be given a great numberof choices in how and when they wish to be contacted by an ePD shipperfor bulk delivered package delivery notification. At a minimum, arecipient (which may or may not be the customer who ordered the items ofthe bulk delivered package) can be required to provide at least onephone number or e-mail address as their primary contact. A recipient canalso provide secondary contact information and can choose to becontacted by both the primary and secondary contacts each time, or to becontacted using the secondary contact only when the primary contactfails. For each contact that a recipient provides to an ePD shipper, therecipient can specify the type of contact (for example, a value such as“phone” for telephone, facsimile, or an alpha-numeric pager reached viaa telephone number or a value such as “e-mail” for e-mail or analpha-numeric pager reached via an internet address), the contact phonenumber or e-mail address, the frequency of which the recipient wishes toreceive reminder messages after the initial notification message (whichcan be measured for example, in the number of hours between remindermessages), and if the contact type is a value such as “phone”, therecipient can specify a calling window start time and end time. Arecipient's notification preference information can be stored on theirCustomer record 1256, and can be updated through an interface connectedto the ePD Billing & Maintenance application, for example, aweb-page-based interface accessible by customers and recipients.

A New Package Notification Program (358) can run as a service on a CDC's1190-1 processing server or a remote server, to set up the informationneeded to trigger an electronic notification to a recipient. The NewPackage Notification Program (358) can work with the Notification Check1310 and Customer 1256 tables to create new and update existing recordson a Notification Queue table 1311. Records on a Notification Queuetable 1311 can be used later by a Notification Program (360) to initiatean electronic notification to notify or remind a recipient to pick up atleast one bulk delivered package at a CDC 1190-1. The New PackageNotification Program (358) can continually monitor and read theNotification Check table 1310 to find the Customer Id on records thatwere written as bulk delivered packages were loaded into SBU's (158).One Notification Check record 1310 can be created for each bulkdelivered package that was loaded into a SBU (158) at a CDC 1190-1. Asthe New Package Notification Program (358) reads each Customer Id on theNotification Check table 1310, it can search the Notification Queuetable 1311 for a record having that Customer Id, to determine whetherthe recipient already has a record on the Notification Queue table 1311or whether a new record should be added to the table for him. Arecipient can already be on the Notification Queue table 1311 if therecipient was added for a different bulk delivered package that therecipient has not yet picked up. In one embodiment, a recipient may onlyhave one Notification Queue record 1311 for a CDC 1190-1 at one time,and that record 1311 can remain until that recipient has unloaded all oftheir bulk delivered packages from the SBU's (158) of that CDC 1190-1.If a recipient already has a record on the Notification Queue table 1311, the program (358) can update the recipient's existing record 1311, forexample, by incrementing the Total Number of Packages field by one andsetting the New Indicator field to a value such as “yes”. If therecipient does not already have a record on the Notification Queue table1311, the New Package Notification Program (358) can use the Customer Idto select information from that recipient's record on the Customer table1256, and create a new record for the recipient on the NotificationQueue table 1311.

The new record can be created on the Notification Queue table 1311 forthe recipient, for example: the Customer Id can be set to the value onthe current Notification Check record 1310; Record Date/Time can be setto the current date/time; Total Number of Packages can be set to “1”;New Indicator can be set to a value such as “Yes”; First NotificationDate/Time, Last Primary Contact Date/Time, Last Secondary ContactDate/Time, and Next Contact Date/Time can have no value (depending uponthe database management system a date/time field having no value canactually have a null value or an initialized date/time value); Number ofPrimary Attempts and Number of Secondary Attempts can be set to “0”;Next Primary Contact Date/Time and Next Secondary Contact Date/Time canhave no value or can be set to the value of the Primary Calling WindowStart Time and the value of the Secondary Calling Window Start Time(both from the Customer record 1256) respectively, depending upon thecurrent time. If the current time precedes, for example, the value ofthe Primary (or Secondary) Calling Window Start Time field on theselected Customer record 1256, the value of the Next Primary (orSecondary) Contact Date/Time field on the Notification Queue record 1311can be set to a date/time value consisting of the current date and thetime of the Primary (or Secondary) Calling Window Start Time. If thecurrent time is later than the Primary (or Secondary) Calling Window EndTime field on the selected Customer record 1256, the value of the NextPrimary (or Secondary) Contact Date/Time can be set to a date/time valueconsisting of the following date and the time of the Primary (orSecondary) Calling Window Start Time. If the current time is between thePrimary (or Secondary) Calling Window Start Time and the Primary (orSecondary) Calling Window End Time, or if the primary (or secondary)contact does not have a calling window defined, the Next Primary (orSecondary) Contact Date/Time can have no value. Whether the New PackageNotification Program (358) updates an existing Notification Queue record1311 or creates a new one when processing a Notification Check record1310, it can delete the Notification Check record 1310 as part of itsprocessing. The program (358) can continue to read Notification Checkrecords 1310 and perform the processing as previously described untilthere are no remaining records on the Notification Check table 1310.After it has processed and deleted all the records on the NotificationCheck table 1310, the New Package Notification Program (358) can monitorthe Notification Check table 1310 for new records to process. The NewPackage Notification Program (358) can be configured to monitor theNotification Check table 1310 at predetermined intervals of time.

The Notification Program (360) is another program, which can runcontinuously on the CDC server or on a remote server as a service. Itcan read the Notification Queue table 1311 and can, for example, comparethe Next Contact Date/Time field of each record against the currentdate/time. If the Next Contact Date/Time has no value or a value priorto the current date/time, the Notification Program (360) can attempt tosend an electronic notification to the recipient using the primaryand/or secondary contact information. If the Next Contact Date/Time islater than the current date/time, the Notification Program (360) canskip the record and evaluate the next one. When the Notification Program(360) finishes reading the last Notification Queue record 1311 listed onthe table, it can return to the first record on the table and repeat itsprocessing to evaluate the remaining records on the table. If theNotification Program (360) is able to skip all the records listed on theNotification Queue table 1311 when making a full pass through the tableto evaluate the records, it can begin another pass through the table toevaluate the records again, after optionally pausing for a predeterminedamount of time. The length of time the Notification Program (360)pauses, if it pauses at all can depend upon how it is configured.

If the Notification Program (360) determines that an electronicnotification should be sent to the recipient on a Notification Queue1311 record, it can compare the Next Primary Contact Date/Time to thecurrent date/time. If the Next Primary Contact Date/Time has no value ora value prior to the current date/time, the program (360) can use, forexample, the value of the Customer Id field to select the Customerrecord 1256 of the recipient for which the notification is being sent,and can then use the data on the Notification Queue 1311 record and theselected Customer record 1256 to compile the input data needed to runeither an Auto-call Program (362) or an Auto-e-mail Program (364).Before compiling the input data, the Notification Program (360) canevaluate the values of the Primary Contact Frequency field on theselected Customer record 1256 and the Last Primary Contact Date/Time onthe Notification Queue record 1311. If the value of Primary ContactFrequency is zero and the Last Primary Contact Date/Time field has avalue, the Notification Program (360) can skip the remaining processingsteps involved in sending a notification message to the primary contact,and can evaluate the value of the Dual Notification Indicator on theCustomer record 1256 to determine if it should compare the NextSecondary Contact Date/Time against the current date/time or beginprocessing the next Notification Queue record 1311. Recipients thatspecify that they do not wish to receive reminder notification messagesafter the first primary or secondary contact is made, can have a valueof zero in the Primary (or Secondary) Contact Frequency field on theirCustomer records 1256.

If the value of the Primary Contact Frequency is not zero or if the LastPrimary Contact Date/Time field has no value, the Notification Program(360) can calculate one input data value—the number of days since thefirst notification—by subtracting the First Notification Date/Time onthe current Notification Queue record 1311 from the current date/timeand rounding down to the number of whole days. The program can compileother input data values by selecting, for example, the Primary ContactNumber/Address value from the Customer record 1256, the FirstNotification Date/Time, Total Number of Packages, and New Indicatorvalues from the Notification Queue record 1311, the current date/time,and the value of the current CDC's 1190-1 address. The value of thecurrent CDC's 1190-1 address can be pre-configured for the instance ofthe program (360) running on the current CDC's 1190-1 server. If thevalue of Primary Contact Type on the selected Customer record 1256 is avalue such as “phone”, the Notification Program (360) can initiate theAuto-call Program (362) and pass it the compiled input data values. TheAuto-call Program (362) can use the Primary Contact Number/Address valueto dial the recipient's phone number and play a pre-recorded message tonotify or remind the recipient that there is at least one bulk deliveredpackage at the CDC 1190-1, ready to be picked up. The pre-recordedmessage can include at least the value of the current CDC's 1190-1address (the values in the Address 1 and Address 2 fields of the currentCDC's 1190-1 record on the CDC table 1252), and can also include, but isnot limited to, the current date/time, the value of the Total Number ofPackages, an indication of whether or not a bulk delivered package hasbeen delivered since the last notification message (determined from theNew Indicator value), the number of days since the first notification(calculated as previously described), the First Notification Date/Time,general shipper policy information (including early pickup incentivediscounts and late pickup penalties), contact information to submitquestions, and other general information.

After the Notification Program (360) calls the Auto-call Program (362),it can increment the value of the Number of Primary Attempts by one onthe Notification Queue record 1311 and wait for the Auto-call Program(362) to finish its processing and return a confirmation output. If theAuto-call Program (362) returns an output indicating that an electronicnotification message was sent successfully, the Notification Program(360) can update the Notification Queue record 1311, for example: if theFirst Notification Date/Time has no value, it can be set to the currentdate/time; Last Primary Contact Date/Time can be set to the currentdate/time; Next Primary Contact Date/Time can be set to the currentdate/time plus the number of hours in the Primary Contact Frequency onthe Customer record 1256 (adjusted to the next earliest Primary CallingWindow Start Time if the calculated value does not fall between thePrimary Calling Window Start Time and the Primary Calling Window EndTime); Number of Primary Attempts can be set to zero; and if the valueof the Dual Notification Indicator on the selected Customer record 1256is a value such as “no”, the Next Contact Date/Time can be set to thesame value as the Next Primary Contact Date/Time field. The updateswhich can be made to the Notification Queue 1311 record by theNotification Program (360) can reset the record to trigger the sendingof another electronic notification message to the Primary ContactNumber/Address after the Primary Contact Frequency interval elapses.

In addition to updating the other fields on the Notification Queuerecord 1311 after receiving a successful confirmation output, theprogram (360) can evaluate the value of New Indicator field on theNotification Queue record 1311. If it is set to a value such as “yes”,the program (360) can reset it to a value such as “no” and selectrecords from the Bin Inventory table 1300 having a Status value such as“loaded” and a Customer Id equal to the value on the Notification Queuerecord 1311. The program (360) can update each selected Bin Inventoryrecord 1300, for example, setting the Status to a value such as“notified” and Notification Date/Time to the value of the Last PrimaryContact Date/Time. The program (360) can also create, for example, a newrecord in a Notification Update data file for each Bin Inventory record1300 it updates, writing the Package Id and Notification Date/Time fromthe updated Bin Inventory record 1300 to the data file. If the NewIndicator field being evaluated has a value such as “no”, the program(360) can continue with its next processing step.

After updating the Notification Queue table 1311, Bin Inventory table1300, and Notification Update data file records following the receipt ofa successful confirmation output for a primary contact, the value of theDual Notification Indicator on the selected Customer record 1256 can beevaluated. If the Dual Notification Indicator field has a value such as“no”, the program (360) can proceed to process the next NotificationQueue record 1311. If it has a value such as “yes” the NotificationProgram (360) can follow processing steps that can be similar to thosedescribed for sending an electronic notification message to the primarycontact, except that the secondary contact information can be read andupdated. One exception to secondary contact processing steps usingsecondary contact information can be that after a successfulconfirmation output is received by the Notification Program (360) for asecondary contact, the Notification Program (360) can update the NextContact Date/Time to the same value as the Next Primary ContactDate/Time field, instead of the value of the Next Secondary ContactDate/Time field. In addition to when the Dual Notification Indicator fora recipient has a value such as “yes”, there can be other situations inwhich the Notification Program (360) can use secondary contactinformation to send an electronic notification message. Those situationscan include, but are not limited to: a situation where the Next ContactDate/Time and the Next Secondary Contact Date/Time are prior to thecurrent date/time, but the Next Primary Contact Date/Time is later thanthe current date/time; and a situation where the output return receivedfrom the Auto-call Program (362) indicates that the primary contactattempt was unsuccessful.

If both the primary and secondary contact attempts are unsuccessful, theNotification Program (360) can proceed to process the next record listedon the Notification Queue table 1311. The Notification Program (360) canattempt to process the unsuccessful record 1311 again on each successivepass it makes through the Notification Queue table 1311, until therecord 1311 gets updated as successful or the Number of Primary Attemptsand Number of Secondary Attempts on the record 1311 reach a predefinedlimit. Once the predefined limits in the number of attempts fields arereached, the Notification Program (360) can reset the values in bothnumber of attempts fields to zero and can reset the Next ContactDate/Time to a future date/time, which can be a predefined time intervalahead of the current date/time.

The Notification Program (360) can process primary and secondarycontacts having a Primary (or Secondary) Contact Type value such as“e-mail” using the same processing steps as described for sending anelectronic notification message for a contact having a Primary (orSecondary) Contact Type value such as “phone”, except that it caninitiate the Auto-e-mail Program (364) instead of the Auto-call Program(362) and it does not need to wait for a confirmation output return fromthe Auto-e-mail Program (364) before continuing its processing. TheNotification Program (360) can assume notification e-mail messages to besent successfully, and can update the Notification Queue table 1311, BinInventory table 1300, and Notification Update data file records in thesame way as it would after receiving a successful confirmation outputfrom the Auto-call Program (362), immediately after it initiates theAuto-e-mail Program (364). The Auto-e-mail Program (364) can use thePrimary (or Secondary) Contact Number/Address to send an e-mail messageto the recipient. The same data input variables that can be passed tothe Auto-call Program (362) can be passed to the Auto-e-mail Program(364) and the text of the prerecorded script used for the phone messagecan be the text of the e-mail message. The same updates can be made tothe Notification Queue table 1311, Bin Inventory table 1300, andNotification Update data file records during processing. Although e-mailnotification messages can be assumed to be sent successfully whentransmitted, an E-mail Error Checking Program (366) can search the inboxof the internet account used by the Auto-e-mail Program (364) forreturned e-mail error messages from unsuccessful e-mail transmissions.The E-mail Error Checking Program (366) can read the e-mail addressreference in the returned e-mail error message, select the Customertable record 1256 containing that e-mail address value in either thePrimary Contact Number/Address or Secondary Contact Number/Address, andcreate a record in a Notification Error data file containing theCustomer Id, the e-mail address causing the error, and the Primary (orSecondary) Contact Number/Address that did not cause the error. TheNotification Error data file can later be used to contact recipients tocorrect invalid e-mail addresses.

The ability for a customer and/or recipient to view the status and CDClocation 1190-1 of items that have been ordered but have not yet pickedup can be provided using, for example, a web-page-based interface, whichcan have read-only access to information on a shipper's RDC and/or CDCservers. In a one aspect of the invention, a customer or recipient canlog into an Internet site specific to a shipper or one that is commonacross many ePD shippers to view delivery information including, but notlimited to, the number of bulk delivered packages currently in a CDC1190-1 for the recipient to retrieve, the SBU Id's of each SBU (158)containing a bulk delivered package for the recipient to retrieve, theelapsed time that each bulk delivered package has been in a CDC 1190-1since notification of delivery was first made, the recipient'snotification preferences, the customer or recipient's ePD AccountBalance, and the Status of any CDC outbound package sent by the customerwhich has not yet been picked up by its package recipient.

In FIG. 6, there is depicted an exemplary Customer Distribution Center(CDC). The CDC of FIG. 6 can comprise the following entities: backroomaisle (132), holding cage (134), backroom video surveillance camera(136), package bag recycling chute (138), package bag recyclingcollection tank (140), package bag recycling machine (142), mobileputaway conveyor unit (143), CDC delivery dock door (144), CDC receivingdock conveyor extension (145), main room delivery entrance door (146),returns processing entry point (148), returns video surveillance camera(150), customer service video conferencing station (152), backroom area(154), returns conveyor (156), SmartBin Unit machine (158), outboundpackage processing workstation (159), side aisle (160), cross aisle(162), temperature controlled storage room door (164), temperaturecontrolled storage room wall (166), temperature controlled SmartBin Unitmachine (168), main aisle (170), entrance station/entrance station door(172), entrance station video surveillance camera (174), exteriorentrance doors (176), inner entranceway area (177), exterior videosurveillance camera (178), exit way video surveillance camera (180),exterior exit door (182), exit aisle (184), interior exit door (186),SmartBin Unit machine—frozen articles (188), returns processingworkstation (189), interior video surveillance camera (190), and holdingcage door (192).

A further embodiment of the invention can include one or more customerservice video conferencing stations (152) located in a CDC 1190-1 thatcan be used by a recipient to contact a customer service worker specificto a shipper or one that supports more than one shipper. The recipientcan ask questions or report a discrepancy involving a bulk deliveredpackage, a CDC outbound package, or an item return package. Therecipient can have the ability to see the customer service worker andtheir immediate surrounding area and the customer service worker canhave the ability to see the recipient and the immediate surrounding areaincluding any packages or nearby SBU's (158), outbound packageprocessing workstations (159), or returns processing workstations (189).Customer service can be provided to recipients and customers acrossevery CDC location 1190-1, 24 hours a day, seven days a week by acentralized group of customer service workers without incurring the costof staffing one or more customer service representatives in everyphysical location. Another aspect can include various interior videosurveillance cameras (190) and exterior video surveillance cameras(178), located at a CDC 1190-1, that can be monitored remotely by asecurity service or a shipper's in-house security personnel. Securitypersonnel based in the local markets can be on call to respond as neededto situations, which may require the interaction of a security worker.Any improper actions can also be captured on video for later use inprosecuting a wrongdoer. Security services can be provided remotely toall CDC locations, 24 hours a day, seven days a week by a centralizedsecurity service working in conjunction with local on-call securityresponse personnel without incurring the cost of staffing one or moresecurity workers in every physical location.

Returning to the notification step 1148, the recipient can retrieve (orpick up) one or more bulk delivered packages as described in step 1150.After receiving one or more notification phone calls, e-mails, or textpage messages, a recipient can travel to the CDC 1190-1 identified inthe notification message (the same CDC 1190-1 which the customerselected as the destination centralized pickup location when thecustomer ordered the items from retailers) to pick-up their bulkdelivered packages. For illustration, the recipient can chose to park inthe CDC's 1190-1 parking lot, walk to the closest package cart keepermachine near their parking space, run their ePD customer access cardthrough the package cart keeper's card reader, and press the releasebutton to release a package cart from the package cart keeper machine.The recipient can push the cart through the parking lot and through theCDC's 1190-1 exterior entrance doors (176), which can automatically openfor the recipient as the recipient approaches them. A sensor can be usedto automatically open the doors (176) using technology similar to thetechnology commonly found on the automatic opening doors of supermarketsand other public places. The recipient can push their cart through theexterior entrance doors (176) and up to one of the entrance stationdoors (172) in the CDC's 1190-1 inner entranceway area (177).

There can be one or more entrance stations (172) located in the innerentranceway area (177) of a CDC 1190-1. Each one can consist of thefollowing components: a card reader, a keypad, a tape printer, a displayscreen, and an electronic locking door. The components can be wired tothe CDC server through networking cables to pass data from the cardreader and keypad components to the CDC server and to pass commands anddata from the CDC server to the display screen, tape printer, andelectronic locking door components of the entrance station (172).

The recipient can run their ePD customer access card through theentrance station card reader and can key in their personalidentification number (PIN) on the entrance station keypad. An ePDcustomer access card can have, for example, a magnetic data strip thatcontains at least the recipient's Customer Id and can optionally includeother data used for security validation. The recipient's actions caninitiate or cause to be initiated, an instance of a Package LocationReport Program (368) to run on the CDC server. The Package LocationReport Program (368) can validate the scanned card and entered PIN byusing the Customer Id on the access card to select the Customer record1256 and then comparing the entered PIN value against the PIN value onthe selected Customer record 1256. If the entered PIN does not match,the Package Location Report Program (368) can, for example, sound anerror tone and/or display an error message on the entrance stationdisplay screen to indicate that the entered PIN is not valid for theaccess card. Alternately, other audio and or visual alerts can be used.If the entered PIN matches, the Package Location Report Program (368)can search the Bin Inventory table 1300 for all the records that have aCustomer Id equal to the one read from the access card. The PackageLocation Report Program (368) can generate and assign, for example, aQuick Code to all of the Bin Inventory records 1300 found for therecipient (having the Customer Id of the scanned access card). The QuickCode can serve as a temporary alias for a recipient's Customer Id andcan be a random number, for example, four digits in length. Ingenerating a random number for the Quick Code, the Package LocationReport Program (368) can validate the generated random number against aQuick Code table 1313 to ensure that the number was not already assignedto another recipient. If the Package Location Report Program (368) findsthe randomly generated number on the Quick Code table 1313 it canattempt to generate a different random number and check it against theQuick Code table 1313 to ensure that it has not already been assigned toa recipient. When the Package Location Report Program (368) generates anumber that is not already listed on the Quick Code table 1313, it canwrite that number to the Quick Code table 1313 and to the Quick Codefield of each Bin Inventory record 1300 it selected for that recipient.Recording assigned Quick Code numbers to the Quick Code table 1313 canensure that no two recipients will have the same Quick Code over acertain time period until Quick Codes are reset. A Quick Code ResetProgram (376), which can be used to reset (delete all Quick Code valuesfrom) the Quick Code table 1313, can be scheduled to run at a differentfrequency in each CDC 1190-1. In one embodiment of the ePD DeliveryProcess, the Quick Code Reset Program (376) can be scheduled to resetthe Quick Code table 1313 each night.

After assigning Quick Codes to the Bin Inventory records 1300 selectedfor the recipient, the Package Location Report Program (368) can createa Location Report listing the Quick Code and all the SBU Id numbers ofthe selected Bin Inventory records 1300. The Location Report can beprinted on the tape printer at the entrance station (172) where therecipient swiped their ePD customer access card and entered their PINnumber. The Location Report can be formatted to have, for example, theQuick Code printed on the top line next to a heading such as “QuickCode=”, a blank second line, and a listing of each SBU Id on a separateline below an underlined header such as “SBU locations”. The SBUlocations can be listed in SBU Id sequence, and if a recipient has morethan one bulk delivered package in a SBU (158), that SBU (158) can belisted once for each bulk delivered package that it holds for thatrecipient. After printing the report, the Package Location ReportProgram (368) can unlock and automatically open the entrance stationdoor (172) for a short period of time to allow the recipient to grab thereport from the tape printer and enter the CDC 1190-1 with their packagecart.

Basic information about using an entrance station (172) can be posted inthe inner entranceway area (177) near the entrance stations (172),including a message to tell recipients to press an instructions key onthe entrance station keypad to print detailed instructions on how tooperate an entrance station, read a Location Report, and operate a SBU(158). When recipients press the instructions key on the entrancestation keypad, the CDC server can print a standard instructions reportlisting the basic instructions on how to maneuver through the CDC1190-1. The printer could be, but is not limited to a tape printer,laser, inkjet, or dot matrix printer or any combination thereof.

Continuing with the illustrative example, after passing through theentrance station door (172), the recipient can walk through the aislesof the CDC 1190-1 using posted SBU location number range signs to guidethem to the SBU's (158) listed on their Location Report. Upon arrivingat each SBU (158) listed on their report, the recipient can key in theQuick Code listed on their report and their PIN using the SBU's keypad(244) to retrieve each bulk delivered package listed on their LocationReport from an SBU (158). When the Quick Code and PIN are keyed in, theinformation can be passed through the SBU (158) and sent to the CDCserver along with the SBU Id of the SBU (158). An Unloading Program(370) of the ePD SBU Application can be initiated and it can search therecords on the Bin Inventory table 1300 having the SBU Id of the SBU(158) from which the data was sent. The Unloading Program (370) cansearch the Bin Inventory records 1300 corresponding to that SBU's binsfor the Quick Code and PIN entered by the recipient. The UnloadingProgram (370) can search for the records 1300 corresponding to a SBU'sstationary bins before searching for the records 1300 corresponding toits revolving bins. If the Unloading Program (370) finds a stationarybin's record 1300 having a Quick Code and PIN that matches the valuesentered by the recipient, it can send a display command to the SBUdisplay screen (246) to display the bin door number or numberscorresponding to the bin containing the recipient's bulk deliveredpackage. The Unloading Program (370) can also send an unlock command tothe bin door locking mechanism of one or more of the stationary bindoors (238), depending upon the configuration of the stationary bins, toopen the bin doors (238) of the bin containing the recipient's bulkdelivered package. The Unloading Program (370) can also, for example,write a new record to a Package Pickup table 1312 and a Pickup Updatedata file, and can update the selected Bin Inventory record 1300 toinitialize it as an available bin.

The Package Pickup table 1312 of the SBU Application can have all thesame fields as the Bin Inventory table 1300 except for Status. It canalso have two additional fields that are not on the Bin Inventory table1300—CDC Id and Pick-up Date/Time. To create the new Package Pickuprecord 1312, the Unloading Program (370) can copy all the data from theBin Inventory record 1300 except for Status. On the new Package Pickuprecord, CDC Id can be set to the value of the current CDC 1190-1 inwhich the application is running, and Pick-up Date/Time can be set tothe current date/time. The Unloading Program (370) can create the newPickup Update data file record by writing the Package Id from theselected Bin Inventory record 1300 and the Pickup Date/Time as thecurrent date/time. To initialize the Bin Inventory record 1300 as anavailable bin, the Unloading Program (370) can set its Status equal to avalue such as “available” and can delete the values from the data fieldsrelated to the bulk delivered package—Customer Id, PIN, Quick Code,Package Id, Delivery Employee Id, Shipper Id, Delivery Date/Time, andNotification Date/Time.

If the Unloading Program (370) finds a revolving bin record matching theQuick Code and PIN, it can call or cause to be called, the BinPositioning Program (372) to determine the movement needed to positionthe master bin containing the recipient's bulk delivered package intothe unloading position. Before calling the Bin Positioning Program(372), the Unloading Program (370) can determine which master bin iscurrently in the unloading position for the current SBU (158) byselecting the Load Position Master Bin Id value from the SBU Settingstable 1314. The Unloading Program (370) can pass the values of theselected Load Position Master Bin Id and the Master Bin Id (from theselected Bin Inventory record 1300) of the bin containing therecipient's bulk delivered package to the Bin Positioning Program (372).The Bin Positioning Program (372) can use the Load Position Master BinId value to search a Bin Movement table 1315 for the movement requiredto move the master bin containing the recipient's bulk delivered packageinto the unloading position. The Bin Movement table 1315 can show themovement needed to move the selected bin into the unloading position,relative to the unloading position if moving in the clockwise direction(when referring to bin movement in this disclosure, moving a SBU's frontbins upward and back bins downward is considered a clockwise direction).For example, if the selected Master Bin Id is “05” and the Master Bin Idcurrently in the unloading position is “03”, the movement needed to moveMaster Bin Id “05” into the unloading position can be “−2”. Since masterbins can be numbered in the clockwise direction, Master Bin Id “05” canbe two positions beyond the unloading position in the clockwisedirection in this example, and would need to be moved counterclockwisefor a distance of two positions. In another example, where the SBU (158)has a total of eighteen bins, the selected Master Bin Id is “17” and theMaster Bin Id in the unloading position is “03”, the required movementneeded to move Master Bin Id “17” into the unloading position can be“4”, because “17” can be four positions away from the unloading positionin the counterclockwise direction and therefore would need to be movedfour positions in the clockwise direction to reach the unloadingposition. If the master bin containing the recipient's bulk deliveredpackage is already in the unloading position the Bin Positioning Program(372) can calculate the required movement to be “0” and bypass the stepof sending a motor command to the SBU (158).

After determining the movement required to move the master bincontaining the recipient's bulk delivered package into the unloadingposition, the Unloading Program (370) can check all the bin door sensorson the revolving bin doors (234) to make sure that all the revolving bindoors (234) are in the closed position before moving the master bins. Ifany of the revolving bin doors (234) are not fully closed (and thuslocked), the Unloading Program (370) can display message on the SBU'sdisplay screen (246) to request the recipient to close the revolving bindoors (234). The SBU (158) can continue to display the message andrefrain from performing any other actions until the doors (234) areclosed. Once all the revolving bin doors (234) are in the closedposition, the Unloading Program (370) can send a motor command, with thebin movement calculated by the Bin Positioning Program (372), to the SBUmotor to move the selected master bin into the unloading position. Theprogram (370) can also send a display command to the SBU display screen(246) to display the bin door number or numbers corresponding to the bincontaining the recipient's bulk delivered package, and it can send aconfiguration command to one or more of the bin door configurationmechanisms to move the bin door configuration bolts into the correctsequence for the Configuration Code of the selected bin. The UnloadingProgram (370) can check the value of the Door Configuration Code fieldon the SBU Settings record 1314 having the current SBU Id to find thecurrent configuration of the revolving bin doors (234), and can compareit to the Configuration Code on the Bin Inventory record 1300 of the bincontaining the recipient's bulk delivered package to determine theneeded configuration commands. If the configuration bolts are already ina workable sequence for the selected bin, then configuration commandsmay not need to be sent. When the SBU motor and bin door configurationmechanisms have completed their actions successfully, the UnloadingProgram (370) can send an unlock command to one or more of the bin doorlocking mechanisms to open the bin doors (234) corresponding to theconfiguration of the selected bin. After successfully unlocking therevolving bin doors (234), the Unloading Program (370) can create andupdate records in a manner consistent with the way it does when itunlocks a stationary bin, writing a new record to the Package Pickuptable 1312 and the Pickup Update data file, and updating the BinInventory record 1300 to initialize it as an available bin. TheUnloading Program (370) can also update the SBU Settings table 1314 whenit unlocks a revolving bin, setting the Load Position Master Bin Idequal to the Master Bin Id value of the selected bin and the DoorConfiguration Code to the value which describes the current position ofthe bin door configuration bolts.

If the SBU gets listed on the recipient's Location Report more thanonce, indicating that there is more than one bulk delivered package forthat recipient in that SBU (158), the recipient can reenter the QuickCode and PIN for each bulk delivered package listed to retrieve the bulkdelivered packages one at a time. This can ensure that the recipientmakes an effort to receive each bulk delivered package and can eliminatethe potential problems of opening several bins from one recipientaction. An example of such a problem being that a recipient can retrievefewer bulk delivered packages than the number released from a SBU (158)and can leave one or more bulk delivered packages behind, which could betaken by another person.

The ePD SBU Application's programs and tables can track information thatcan be used by shippers to administer financial incentives when bulkdelivered packages get picked up early or financial penalties when bulkdelivered packages get picked up late. Each shipper can set their ownpolicies regarding incentives and penalties, and those policies can bechanged at the discretion of each shipper. The data used to trackrecipient pick up activity can be captured on the Package Pickup table1312 as recipients remove their bulk delivered packages from SBU bins.Pickup Date/Time can be compared against Notification Date/Time on thePackage Pickup table 1312 to determine how long a bulk delivered packageremained in a SBU bin following delivery notification. A running totalof the net cumulative incentive discount or penalty charge can becalculated and tracked for each shipper or in total across all shippers,for a customer or recipient, in a field such as an ePD Account Balancefield on a Customer record 1256.

If a recipient accidentally locks a SBU bin with their bulk deliveredpackage still inside, for example, by pushing it closed when trying toretrieve the bulk delivered package from the SBU (158), the recipientcan open the bin again, for example, by pressing a “re-open” key or keysequence on the SBU keypad (244) and then keying in their Quick Code andPIN again. The re-open feature can re-open a bin on a SBU (158) that therecipient had previously opened using the same entered Quick Code andPIN. When the recipient presses the “re-open” key or key sequence, theSBU (158) can send a re-open request including the SBU Id and theentered Quick Code and PIN to the CDC server. A Re-open Program (374)can be initiated and can search the Package Pickup table 1312 for arecord matching the SBU Id, Quick Code, and PIN sent from the SBU (158).If the recipient had retrieved more than one bulk delivered package fromthe SBU (158), the Re-open Program (374) can select all the records1312, and process them in sequence of Pick-up Date/Time starting withthe latest one. The Re-open Program (374) can function in the same wayas the Unloading Program (370) with some exceptions. Instead of readingdata from the Bin Inventory table 1300, the Re-open Program (374) canread data from the Package Pickup table 1312. The Re-open Program (374)doesn't need to update a Bin Inventory record 1300 to initialize it. TheRe-open Program (374) doesn't write new records to the Package Pickuptable or the Pickup Update data file. Also, after the Re-open Program(374) finds the Bin Id on the Package Pickup table 1312, it can checkthe Status of that Bin Id on the Bin Inventory table 1300 prior totaking any action. If the Status is a value such as “available”,“re-open”, or “configuration reserved” the Re-open Program (374) canperform the actions required to re-open the bin. If the Status does notequal a value such as “available”, “re-open”, or “configurationreserved” the Re-open Program (374) can check the next selected PackagePickup record 1312 if more than one was selected, until it finds onehaving a corresponding Bin Inventory record 1300 with a Status valuesuch as “available”, “re-open”, or “configuration reserved”. If theRe-open Program (374) cannot find a Bin Id on a selected Package Pickuprecord 1312 which has the appropriate status on its corresponding BinInventory record 1300, the Re-open Program (374) can, for example, soundan error tone and/or displays an error message indicating that there areno bins in the SBU (158) corresponding to the entered Quick Code andPIN.

The re-open feature can be used when a recipient mistakenly pushes thebin door (234 or 238) closed when trying to retrieve their bulkdelivered package. In that situation, the result of the Re-open Program(374) can be to re-open a stationary bin or a revolving bin that isalready in the unloading position. If the recipient does not use there-open feature immediately after closing the bin door (234 or 238) (ifthey are unaware of the re-open feature and confused as to what to do),they can come back at a later time and use the re-open feature toretrieve their bulk delivered package. If a recipient does come back touse the re-open feature at a later time, the Re-open Program (374) canmove the bin containing the recipient's bulk delivered package to theunloading position before unlocking the bin, if the bins have been movedsince the recipient originally tried to retrieve the bulk deliveredpackage. When loading bulk delivered packages into a SBU (158), if a CDCworker comes across a bin having a bulk delivered package in it and aBin Inventory record 1300 with a Status value such as “available”, theworker can update the Status of the Bin Inventory record 1300corresponding to the bin, changing it from a value such as “available”to a value such as “re-open”. The worker can, for example, scan a“re-open” status update barcode on their scan commands sheet, thepackage label barcode of the bulk delivered package already in the bin,and the bin door label of the bin containing the bulk delivered packageto cause the Loading Program (356) to update the Bin Inventory record1300 corresponding to that bin to reflect that the bulk deliveredpackage has been ‘reloaded’ with a Status value such as “re-open”. Inthis situation, the CDC worker should not remove the bulk deliveredpackage and load another bulk delivered package into the bin. If thebulk delivered package becomes lost, the next worker to load a bulkdelivered package into a bin which previously contained a bulk deliveredpackage that a recipient has claimed to have not retrieved can be easilyidentified.

When the recipient has retrieved all of their bulk delivered packagesfrom the CDC 1190-1, the recipient can exit the CDC 1190-1 with theirpackage cart of bulk delivered packages by walking through the interiorexit door (186), the exit aisle (184), and the exterior exit door (182).Both the interior exit door (186) and the exterior exit door (182) canhave sensors that can automatically open the door for persons exitingfrom the inside. This makes it easy for recipients to exit through theexit corridor, while making it difficult for someone to enter the CDC1190-1 through the exit corridor. The recipient can push their packagecart to their car and unload their bulk delivered packages into theircar. The recipient can then return the package cart to the package cartkeeper machine closest to their car, for example, by pushing the packagecart into the package cart keeper machine, running their ePD access cardthrough the machine's card reader, and pressing a “return” button tocredit their account for returning the package cart. The package cartkeeper system can be similar to the luggage cart systems used inairports that charge customers a fee to use the carts, and in some casesrefund part of the fee back to the customer upon returning the cart. Inone embodiment of the ePD Delivery Process, recipients do not getcharged for using package carts at CDC's 1190-1 as long as they returnthem to one of the package cart keeper machines. If a recipient does notreturn a cart, they can be charged a fee, for example, through their ePDaccount. This type of cart system can be used to provide recipients withthe convenience of using a cart to carry their bulk delivered packages,at no cost. At the same time, it can discourage recipients from leavingcarts randomly in the parking lot or CDC 1190-1 and can eliminate theneed (and the associated labor cost) of having workers on site at eachCDC 1190-1 to collect and organize the carts, as is done, for example atmany supermarkets. It should be noted that a recipient does not have toacquire a cart to retrieve a package and a CDC can choose not to employa package cart system without departing from the spirit of theinvention.

Following the notification update step 1148, the retailer billing step1138 can be followed as described. A Notification Update data file canbe sent from the CDC server to the RDC server at predefined intervals.The CDC Id and the current date/time can be written as part of the datafile header information. A Notification Update Program (347) can run ona RDC server and can process each Notification Update data filereceived. As the Notification Update Program (347) reads through eachrecord in the data file, it can select all the Order Detail records 1202having the Package Id of the current Notification Update data filerecord. The Notification Update Program (347) can update the selectedOrder Detail records 1202, setting their Status to a value such as“notified” and their Notification Date/Time to the value on the currentNotification Update data file record. After updating the selected OrderDetail records 1202, the Notification Update Program (347) can use eachunique Order Id of the updated Order Detail records 1202 to select allthe Order Detail records 1202 having that Order Id. From each group ofOrder Detail records 1202 selected by Order Id, the Notification UpdateProgram (347) can attempt to select records that do not have a Statusvalue such as “notified” or “picked up” to determine if there are anyOrder Detail records 1202 of that order, which are not in bulk deliveredpackages for which the recipient has been notified of delivery. If theNotification Update Program (347) can find a group of Order Detailrecords 1202 in which every record has a Status value such as “notified”or “picked up”, it can select the Order Header record 1200 having theOrder Id of the group and update that Order Header record's 1200 Statusto a value such as “delivered”.

A Billing Program (349) can run on the RDC server at each RDC to createa billing output data file for the shipper running that RDC. Billingoutput data files created for a shipper can be used by that shipper'sbilling application to bill retailers for delivered orders. To createthe billing data file for a shipper, the Billing Program (349) canselect records from the Order Header table 1200 having the ePD ShipperId of that shipper and a Status value such as “delivered”. Order Headerrecords 1200 with a Status such as “delivered” can represent customerorders for which all ordered items have been loaded as bulk deliveredpackages into SBU's (158) at a CDC 1190-1, prior to at least oneelectronic notification message being sent successfully to therecipients to notify them of the bulk delivered package delivery. As theBilling Program (349) processes each selected Order Header record 1200,it can use the Order Id, on the Order Header record 1200, to select theassociated Order Detail records 1202. The Billing Program (349) cancheck the Status of the Order Detail records 1202 to determine if theentire order has been picked up by the recipient (if the Status of allthe selected Order Detail records 1202 has a value such as “picked up”).If the Status of all associated Order Detail records 1202 has a valuesuch as “picked up”, the Billing Program (349) can set the Status of thecurrent Order Header record 1200 to a value such as “picked up”. If theStatus of any one of the associated Order Detail records 1202 does notequal a value such as “picked up”, the Billing Program (349) can set theStatus of the current Order Header record 1200 to a value such as“billed”.

The Pickup Update data file can be sent from a CDC server to a RDCserver at predefined intervals. The CDC Id and the current date/time canbe written as part of the data file header information. A Pickup UpdateProgram (348) can run on a RDC server and can process each Pickup Updatedata file received. As the Pickup Update Program (348) reads througheach record in the data file, it can select all the Order Detail records1202 having the Package Id of the current Pickup Update data filerecord. The Pickup Update Program (348) can update the selected OrderDetail records 1202, setting their Status to a value such as “picked up”and their Pickup Date/Time to the value on the current Pickup Updatedata file record. The Pickup Update Program (348) can also select thePackage record 1234 having the Package Id of the current Pickup Updatedata file record and can update its Status to a value such as “pickedup”. After updating the selected Order Detail records 1202 and Packagerecord 1234, the Pickup Update Program (348) can use each unique OrderId of the updated Order Detail records 1202 to select all the OrderDetail records 1202 having that Order Id. From each group of OrderDetail records 1202 selected by Order Id, the Pickup Update Program(348) can attempt to select records that do not have a Status value suchas “picked up” to determine if there are any Order Detail records 1202of that order, which can be in bulk delivered packages that have notbeen retrieved by the recipient. If the Pickup Update Program (348) canfind a group of Order Detail records 1202 in which every record has aStatus value such as “picked up”, it can select the Order Header record1200 having the Order Id of the group and can update that Order Headerrecord's 1200 Status to a value such as “picked up” if its existingStatus is a value such as “billed”. If the existing Status on an OrderHeader record 1200 is a value such as “delivered”, the Pickup UpdateProgram (348) can refrain from updating the Order Header record's 1200Status. A Status such as “picked up” on Order Header 1200, Order Detail1202, and Package 1234 records does not affect the billing process, butcan provide information, which can be used in answering package pickupinquiries.

In another aspect of the invention, recipients can return ordered itemsback to a retailer using the infrastructure of the ePD Delivery Process.There is shown in FIG. 13, an illustrative embodiment depicting thesteps that can be used to efficiently return an ordered item to aretailer. Recipients can return ordered items at a CDC 1190-2 byinitiating a CDC Returns Program (378) of the ePD SBU Application whichcan be running, for example, on a returns processing workstation (189).To initiate the CDC Returns Program (378) to process the return of anordered item and create an item return package, step 1400, a recipientcan bring the ordered item and the packing list associated with the itemto a returns processing workstation (189) in a CDC 1190-2. The recipientcan run an ePD customer access card through a card reader and key intheir PIN number. The card reader can be located at the workstation(189), and the workstation's keyboard can be used to key in the PIN.This can be used to initiate the item return transaction. The recipientcan use, for example, a hand-held barcode scanning device that cancommunicate with the workstation (189) to scan the item return barcodeon the packing list associated with the item being returned. Suchcommunication can be wireless or wired. The recipient can use theworkstation's keyboard to key in the quantity of the item beingreturned, select a return reason from a predefined list, and type in acomment related to the returned item. Where no appropriate option isavailable in the list, the recipient can select a return reason such as“other” and can enter a personal reason in the comment field. The CDCReturns Program (378) can validate that the entered PIN matches the PINon the Customer record 1256 having the Customer Id of the ePD customeraccess card which was read by the card reader, and that the Customer Idfrom the ePD customer access card matches the Customer Id embedded inthe Package Id of the scanned item return barcode. An item returnbarcode can contain, but is not limited to the following: the PackageId, Order Id, and SKU of an ordered item. If one of the CDC ReturnsProgram's (378) validation checks fails, the CDC Returns Program (378)can, for example, sound an error tone and/or display a messageexplaining which scanned and/or entered information failed itsvalidation. With reference to FIG. 9F, if the entered and/or the scannedinformation passes the CDC Returns Program's (378) validation checks,the CDC Returns Program (378) can create a record on an Item ReturnHeader table 1266 and an associated record on an Item Return Detailtable 1268 for the item return transaction.

The term “retailer” can be referring to one of a retailer's ormanufacturer's or other equivalent business' order fulfillmentoperations, if they operate multiple order fulfillment operations. If aretailer does operate multiple order fulfillment operations, each onecan be identified by its own ePD Retailer Id. A retailer's item returnsprocessing facility can be identified by a Returns Facility Id, can havea Returns Local Market Id associated with it, and can be assigned toeach distinct ePD Retailer Id on the Retailer table 1246. Beforecreating a new Item Return Header 1266 and Item Return Detail records1268, the CDC Returns Program (378) can select the ePD Shipper Id fromthe record on the RDC table 1258 having the RDC Id embedded in thePackage Id of the scanned item return barcode. The CDC Returns Program(378) can also select the Returns Local Market Id from the record on theRetailer table 1246 having the ePD Retailer Id embedded in the Order Idfrom the scanned item return barcode. After selecting the ePD Shipper Id(of the original bulk delivered package) and the Returns Local Market Id(of the retailer of the original bulk delivered package) the CDC ReturnsProgram (378) can select the RDC Id from the RDC-Local Market table 1264having the selected ePD Shipper Id value and a Local Market Id equal tothe value of the selected Returns Local Market Id (the RDC associatedwith the shipper for that retailer's returns facility—referred to as theorigination RDC for the current item return package). The new ItemReturn Header record 1266 can be created with, for example, the selectedePD Shipper Id, Returns Local Market Id, and RDC Id values, the CustomerId from the ePD customer access card, the current CDC Id, a Status valuesuch as “in CDC”, the ePD Retailer Id embedded in the Order Id from thescanned item return barcode, and an Item Return Creation Date/Time equalto the current date/time. The Item Return Detail record 1268 can becreated with, for example, the SKU, Package Id, and Order Id from thescanned item return barcode and the Return Quantity, Return Reason Code,and Return Reason Comment that the recipient entered and selected usingthe workstation keyboard. The Item Return Id on both new records can beset, for example, to a concatenation of the ePD Retailer Id+CustomerId+CDC Id+current date+a value such as “IR”+a sequential 3 digit number.After a recipient performs the actions to initiate the return of an itemand the CDC Returns Program (378) successfully creates a new record onthe Item Return Header 1266 and Item Return Detail 1268 tables, the CDCReturns Program (378) can, for example, sound a confirmation tone,display a confirmation message to confirm that the item returntransaction has been recorded successfully, print an item return packagelabel, and start a returns conveyor (156). The item return package labelcan include, but is not limited to the following information: the RDCId, Returns Local Market Id, and Item Return Id printed in readableformat and the Item Return Id printed in barcode format.

The recipient can return another item from the same packing list or adifferent packing list by scanning its item return barcode, keying inthe Return Quantity, selecting a Return Reason Code, and entering aReturn Reason Comment. If a subsequent item being returned is from thesame packing list or from a different packing list that is from the sameretailer, an additional Item Return Detail record 1268 can be createdfor that item return transaction with the same Item Return Id as therecords 1268 created for the previous item return transaction (sinceboth transactions are for the same retailer). If a subsequent item beingreturned comes from a packing list of a different retailer, the CDCReturns Program (378) can create a new set of Item Return Header 1266and Item Return Detail 1268 records and can print a new item returnpackage label for the item return transaction. A new item return packagelabel can be created for each new set of Item Return Header 1266 andItem Return Detail 1268 records.

Recipients can be instructed to separate items being returned todifferent retailers into separate item return packages and to combinedifferent items being returned to the same retailer into one item returnpackage, as the size of a package bag allows. In one aspect of theinvention, a recipient can place the items the recipient is returning,and their associated packing lists, into separate package bags byretailer, affix item return package labels to the item return packagesto which they correspond, seal the item return packages, and place themthrough a returns processing entry point (148) and onto a returnsconveyor (156). Package bags and package ties in which the recipientoriginally received the items the recipient is returning or new packagebags and package ties available from packing materials dispensers at areturns processing workstation (189) can be used to create an itemreturn package. An item return label should be placed over top of anexisting package label, if one exists on a package bag. A returns videosurveillance camera (150) can be located at a returns processingworkstation to record, in a digital data file, moving video or stillphotos of a recipient's actions in placing items being returned intopackage bags and placing those package bags through the returnsprocessing entry point (148). A shipper's return policy can includerequiring a recipient to clearly show their actions in processing anitem return in front of a returns video surveillance camera (150).

An item return can be performed at any CDC 1190-2 running the CDCReturns Program (378), regardless of to which CDC 1190-2 the bulkdelivered package that contained the items was originally delivered.Even items, in packages that were moved through a LDDH 1192-2 anddelivered directly to customer specified addresses, can be returnedusing the CDC Returns Program (378) at a CDC 1190-2. In a further aspectof the invention, the ePD Delivery Process can also allow a customer tosend a package to a CDC 1190-2 or a specific address for a recipientthrough a method similar to processing an item return. There is alsoshown in FIG. 13, an illustrative embodiment depicting the steps thatcan be used to enable a customer to efficiently ship a package from oneCDC 1190-2 to another CDC 1190-3 for a recipient. A customer or someonesending a package, can create a CDC outbound package for a recipient,step 1401, for example, by putting items in an ePD package bag andsealing it using an ePD package tie. In step 1401, larger items suitablefor shipping (packed in a large box or container or wrapped withprotective material to prevent damage) can also be shipped as a CDCoutbound package, provided the larger items are not larger than thelargest configurable SBU bin, if shipping to a CDC 1190-2. A packagesender can use a package bag and package tie from a bulk deliveredpackage the package sender had previously received, or the packagesender can take a new package bag and package tie from the packingmaterials dispensers at an outbound package workstation (159). A packagesender can bring a package that the package sender wishes to send, a CDCoutbound package, to an outbound package processing workstation (159) atany CDC 1190-2 in which the shipper, that the package sender intends todeliver their package, accepts CDC outbound packages. An electronicscale can be connected to, for example, an outbound package processingworkstation (159) and can be used to calculate a package sender's ePDshipping cost based upon several factors that can be defined differentlyfor each shipper. Those shipping cost factors can include, but are notlimited to Delivery Type, Weight, Package Size, Origination CDC Id, andDestination CDC Id. In one aspect of the invention, a credit card/bankdebit card reader with a connection to a payment transaction validationservice can be located at and connected to an outbound packageprocessing workstation (159) to enable credit cards and debit cards tobe authorized and accepted as payment options. In a further aspect ofthe invention, a package sender can also have an ePD account, which canbe debited as a payment option for the cost of shipping a CDC outboundpackage.

The package sender can run an ePD access card through, for example, theworkstation's card reader, key in their PIN number on the workstation'skeypad, select a shipper from a predefined list, select the type ofdelivery—either ePD delivery to a CDC 1190-2 or LDDH delivery to aspecific address—and place their CDC outbound package on the outboundpackage processing workstation's electronic scale. If the delivery typeselected was ePD delivery, the package sender can then key in or selectthe Customer Id of their CDC outbound package's recipient and select theCDC Id of the destination centralized pickup location (or CDC) 1190-2where the package sender wants the package to be delivered, from apredefined list. A package sender can search through a listing ofCustomer Id's on the outbound package workstation (159) using othercustomer information related to the package recipient including, but notlimited to Last Name to find the package recipient's Customer Id. Thepredefined list containing CDC Id's of potential CDC locations 1190-2can also be narrowed using information related to the package recipientincluding, but not limited to Zip and City. If the LDDH delivery typewas selected, the package sender can then type in the name of therecipient and the specific address to which the package sender wants theCDC outbound package to be delivered.

A CDC Outbound Package Creation Program (380) of the ePD SBU Applicationcan validate the entered PIN against the Customer record 1256 of theCustomer Id read from the ePD customer access card and can create arecord on a CDC Outbound Package table 1270. Before creating the new CDCOutbound Package record 1270, the CDC Outbound Package Creation Program(380) can use, for example, the entered/selected information, theelectronic scale reading, and a CDC Outbound Package Cost Calculationtable 1317 to determine the cost the selected shipper will charge forshipping the current CDC outbound package from the current CDC 1190-2 toa selected CDC 1190-3 or specific address. If a shipper bases the coston Package Size as well as weight, the CDC Outbound Package CreationProgram (380) can prompt the package sender to enter the estimated sizeof the package based upon guidelines that the shipper can provide. TheCDC Outbound Package Creation Program (380) can, for example, sound amessage alert tone and display a message on the workstation's displaymonitor to communicate the shipping cost of the CDC outbound package andprompt the package sender to select a form of payment. The packagesender can choose to cancel the transaction or select a form of paymentand run their credit card or debit card through the credit card/bankdebit card reader to initiate a payment authorization request.

Upon receiving a successful credit/debit authorization or the selectionof a payment option that does not require a payment authorization (suchas an ePD account or a shipper account), the CDC Outbound PackageCreation Program (380) can use the CDC Id of the selected destinationCDC 1190-3 to select the Local Market Id associated with the destinationCDC 1190-3 from the CDC table 1252, and can then use that selected LocalMarket Id and the ePD Shipper Id selected by the package sender toselect the RDC Id from the RDC-Local Market table 1264 associated withthe shipper and local market of the destination CDC 1190-3. If theDelivery Type of a CDC outbound package is a value such as “LDDH”, theCDC Outbound Package Creation Program (380) can use the Delivery Zipentered by the package sender and the Zip Code-CDC 1254 and CDC 1252tables to determine the CDC Id and Local Market Id associated with theLDDH 1192-3 that delivers to the delivery address specified by thepackage sender. The CDC Outbound Package Creation Program (380) can thenuse that determined Local Market Id and the selected ePD Shipper Id todetermine the RDC Id associated with that LDDH 1192-3. In one aspect ofthe invention, the CDC Outbound Package Creation Program (380) cancreate a new record on the CDC Outbound Package table 1270 for the CDCoutbound package transaction, for example, as follows: RDC Id can be setto the value selected from the RDC-Local Market record 1264; LocalMarket Id can be set to the value selected from the CDC record 1252; CDCOutbound Package Id can be set to a concatenation of the Customer Id ofthe package recipient+the Origination CDC Id (the CDC Id of the currentCDC 1190-2)+the current date+a sequential 3 digit number; Status can beset to a value such as “in origination CDC”; ePD Shipper Id can be setto the value of the shipper selected by the package sender; ShippingCustomer Id can be set to the value read from the ePD customer accesscard; Delivery Type can be set to the value selected by the packagesender; Origination CDC Id can be set to the value of the current CDC1190-2; Recipient Customer Id can be set to the value entered by thepackage sender or can be created with no value if Delivery Type has avalue such as “LDDH”; Destination CDC Id can be set to the valueselected by the package sender or can be selected from the Zip Code-CDCtable 1254 if Delivery Type has a value such as “LDDH”; Temperature Codecan be set to a value such as “standard” (packages requiringrefrigeration or freezer storage cannot be shipped as CDC outboundpackages); Weight can be set to the value read from the workstation'selectronic scale; Cost can be set to the value calculated by the CDCOutbound Package Creation Program (380)—by comparing the informationentered by the package sender against the CDC Outbound Package CostCalculation table 1317; Delivery Name, Delivery Address 1, DeliveryAddress 2, Delivery City, Delivery State, and Delivery Zip can be set tothe values entered by the package sender (or can be created with novalue if Delivery Type is a value such as “ePD”); Payment Method can beset to the method selected by the package sender; Payment Card Numbercan be set to the card number of the credit or debit card run throughthe credit card/bank debit card reader; and Payment Authorization Numbercan be set to the value returned from a successful credit card or debitcard authorization request.

After the customer performs the actions that can be used to ship a CDCoutbound package and the CDC Outbound Package Creation Program (380)successfully creates a new record on the CDC Outbound Package table1270, the CDC Outbound Package Creation Program (380) can, for example,sound a confirmation tone, display a confirmation message to confirmthat the CDC outbound package has been recorded successfully, print anoutbound package label, and start the returns conveyor (156). Theexemplary outbound package label can include, but is not limited to, thefollowing information: the RDC Id, Destination CDC Id, CDC OutboundPackage Id, Delivery Name, Delivery Address 1, Delivery Address 2,Delivery City, Delivery State, and Delivery Zip printed in readableformat and the CDC Outbound Package Id printed in barcode format. Thepackage sender can affix the package label to the CDC outbound package(over top of any existing package labels) and can place the CDC outboundpackage through the returns processing entry point (148) and onto thereturns conveyor (156).

In one aspect of the invention, CDC workers can organize item returnpackages and CDC outbound packages into CDC reverse shipments using aCDC Reverse Shipment Creation Program (382) in step 1402. The CDCReverse Shipment Creation Program (382) can run, for example, on aworkstation in the backroom area (154) of a CDC 1190-2. After startingthe CDC Reverse Shipment Creation Program (382) a CDC worker can scantheir employee id card and begin scanning the barcodes on the labels ofitem return packages and CDC outbound packages as the worker puts theminto cargo cages. A CDC worker can look for the RDC Id on the label ofan item return package or a CDC outbound package to determine if it is apackage for the shipper for whom the worker works. The CDC ReverseShipment Creation Program (382) can validate that the first scanned itemreturn package or CDC outbound package is associated with the shipperwith whom the CDC worker is employed, by using the Item Return Id of thescanned item return label or the CDC Outbound Package Id of the scannedCDC outbound package label to select the ePD Shipper Id from the ItemReturn Header 1266 or CDC Outbound Package record 1270, and comparing itagainst the ePD Shipper Id selected from the Employee table record 1308having the Employee Id of the scanned employee id card. If the firstpackage, scanned after the employee id card is scanned, passes the CDCReverse Shipment Creation Program's (382) validation, the CDC ReverseShipment Creation Program (382) can create a new CDC reverse shipment bycreating a new record on a CDC Reverse Shipment table 1274. In a furtheraspect of the invention, in order to create the new CDC Reverse Shipmentrecord 1274, the CDC Reverse Shipment Creation Program (382) can selectthe Local Market Id from the CDC table record 1252 of the current CDC1190-2 and use it along with the ePD Shipper Id value, selected from theEmployee table 1308 during the CDC Reverse Shipment Creation Program's(382) validation, to select a RDC Id from the RDC-Local Market table1264. The CDC Reverse Shipment Creation Program (382) can create the newCDC Reverse Shipment record 1274, for example, as follows: OriginationRDC Id can be set to the selected RDC Id value; CDC Reverse Shipment Idcan be set to a concatenation of the current CDC Id+the current date+avalue such as “RS”+a 3 digit sequential number; Status can be set to avalue such as “in CDC”; CDC Id can be set to the value of the currentCDC 1190-2; ePD Shipper Id can be set to the value selected from theEmployee table 1308 during the program's (382) validation; and ShipmentCreation Employee Id can be set to the value from the scanned employeeid card.

As a CDC worker scans subsequent item return packages and CDC outboundpackages, the CDC Reverse Shipment Creation Program (382) can validatethat each scanned item return package or CDC outbound package isassociated with the shipper with whom the CDC worker is employed usingthe same validation that it used for the first item return package orCDC outbound package added to the CDC reverse shipment. If a scannedpackage does not pass the CDC Reverse Shipment Creation Program's (382)validation, the CDC Reverse Shipment Creation Program (382) can, forexample, sound an invalid tone and display a message that the scannedpackage is for a different shipper. If a scanned package passes the CDCReverse Shipment Creation Program's (382) validation, the CDC ReverseShipment Creation Program (382) can update, for example, the Item ReturnHeader record 1266 or CDC Outbound Package record 1270 of the scanneditem return package or CDC outbound package, to set its Status to avalue such as “CDC reverse shipment” and its CDC Reverse Shipment Idfield to the CDC Reverse Shipment Id of the current CDC reverse shipmentbeing created.

The CDC worker can stop adding item return packages to a CDC reverseshipment at any time by, for example, selecting a program option toprint a CDC reverse shipment label. A CDC worker can create differentsized CDC reverse shipments depending upon when the worker decides toprint the CDC reverse shipment label. The worker can, for example, peelthe CDC reverse shipment label from its label stock, affix it to a labelplate, and slide the label plate into the cargo cage label plate holderof one of the cargo cages containing the item return packages and CDCoutbound packages that the worker grouped together into a CDC reverseshipment. Information printed on a CDC reverse shipment label caninclude, but is not limited to, the CDC Reverse Shipment Id and ePDShipper Id in a readable format and the CDC Reverse Shipment Id in abarcode format.

In another aspect of the invention, after a tractor-trailer finishesunloading all of its delivery shipments in a local market, it can stopat one or more CDC's 1190-2 within that local market to pick up CDCreverse shipments, step 1404. A team of CDC workers and atractor-trailer driver can coordinate with each other to meet at a CDC1190-2 to load CDC reverse shipments onto a tractor-trailer (200 & 202)bound for a RDC 1180-2 which serves the local market in which that CDC1190-2 is located. The CDC workers can start a CDC Reverse ShipmentProgram (384) of the ePD SBU Application on a workstation in thebackroom area (154) of a CDC 1190-2. After starting the CDC ReverseShipment Program (384), a CDC worker can scan their employee id card,the Trailer Id barcode on the trailer door label, and the label on eachCDC reverse shipment being loaded onto the trailer (202). Mobile putawayconveyor units (143), a CDC receiving dock conveyor extension (145), andthe trailer conveyor (204) of the tractor-trailer (200 & 202) can beused to load the cargo cages and large packages of CDC reverse shipmentsonto the tractor-trailer (200 & 202).

As the label on each CDC reverse shipment is scanned, the CDC ReverseShipment Program (384) can update the CDC Reverse Shipment record 1274of the scanned label, for example, as follows: Status can be set to avalue such as “in-transit”; Loading Employee Id can be set to the valuefrom the scanned employee id card; Trailer Id can be set to the value ofthe scanned Trailer Id barcode; and CDC Reverse Shipment Date/Time canbe set to the current date/time. After the updates are made to CDCReverse Shipment records 1274, the CDC Reverse Shipment Program (384)can create data files from the CDC Reverse Shipment 1274, Item ReturnHeader 1266, Item Return Detail 1268, and CDC Outbound Package 1270tables on the CDC server. The data files can be created to move therecords from the database on the CDC server to the database on the RDCserver, and each data file can have the same fields as the table fromwhich it can be created. In one aspect of the invention, the CDC ReverseShipment Program (384) can create a CDC Reverse Shipment data file byselecting records from the CDC Reverse Shipment table 1274 using the CDCReverse Shipment Id of each scanned CDC reverse shipment label as theCDC reverse shipments are loaded onto the tractor-trailer (200 & 202).

After each CDC Reverse Shipment data file record is created, the CDCReverse Shipment Program (384) can select all the Item Return Headerrecords 1266 and CDC Outbound Package records 1270 having the CDCReverse Shipment Id of the scanned CDC Reverse Shipment label and cancreate an Item Return Header data file and a CDC Outbound Package datafile respectively. As the CDC Reverse Shipment Program (384) is creatingthe Item Return Header data file it can also create an Item ReturnDetail data file by selecting records from the Item Return Detail table1268 having the Item Return Id of the records being written to the ItemReturn Header data file.

A CDC reverse shipment containing item return packages and CDC outboundpackages can be shipped from an origination CDC 1190-2 to an originationRDC 1180-2 in step 1406. After CDC reverse shipments have been loadedonto the trailer (202), the tractor-trailer (200 & 202) can leave thecurrent origination CDC 1190-2 to proceed to the current shipper'sorigination RDC 1180-2 which serves the current CDC 1190-2, or toanother CDC 1190-2 in the local market to pick up more CDC reverseshipments, or to a retailer fulfillment site 1194-2 (FIG. 2) in thelocal market to pick up retailer shipments. Also shown in FIG. 2, is aretailer fulfillment site 1194-3 and a retailer fulfillment site 1194-4.A CDC worker running the CDC Reverse Shipment Program (384) can end theCDC Reverse Shipment Program (384) by, for example, selecting an optionto transmit the data files related to the CDC reverse shipment. The CDCReverse Shipment Program (384) can transmit, for example, the ItemReturn Header, Item Return Detail, CDC Outbound Package, and CDC ReverseShipment data files via a file transport program to the RDC server ofthe shipper's RDC 1180-2 which serves the current CDC 1190-2 (the RDC Idselected from the RDC-Local Market table 1264 having the current ePDShipper Id and the local market of the current CDC 1190-2). When thedata files are received onto the RDC server, a Receive RDC ReverseShipment Data Program (317) of the shipper's instance of the ePDShipping Application can read each data file and write the data to thetables corresponding to each data file (having the same name) in the ePDShipping Application's database on the RDC server. As the Receive RDCReverse Shipment Data Program (317) reads through each record in a datafile it can add a new record to the corresponding table and update theStatus on each data file record to a value such as “record received”.When processing Item Return Header and Item Return Detail data files toadd records to their corresponding tables, the Receive RDC ReverseShipment Data Program (317) can process the files together by firstwriting an Item Return Header record 1266 and then writing the ItemReturn Detail records 1268 that have the Item Return Id of that ItemReturn Header record 1266. With reference to FIG. 9G, as the Receive RDCReverse Shipment Data Program (317) writes the first Item Return Detailrecord 1268 corresponding to an Item Return Header record 1266, it canuse, for example, the Order Id of that Item Return Detail record 1268 toselect the Order Delivery Type, CDC Id, Retailer Order Number, and OrderDate/Time values from either the Order Header record 1200 or an OrderHeader History record 1278 having that Order Id. In another aspect ofthe invention, a data archiving process can be employed to write OrderHeader 1200 and Order Detail 1202 records to an Order Header Historytable 1278 and an Order Detail History table 1280 respectively, after anentire order has been billed and picked-up. The Receive RDC ReverseShipment Data Program (317) can use the selected Order Header 1200 (orOrder Header History 1278) data to update the Item Return Header record1266, for example, as follows: Original Order Delivery Type can be setto the Order Delivery Type value selected from the Order Header 1200 orOrder Header History 1278 record; and Original Order CDC Id can be setto the CDC Id value selected from the Order Header 1200 or Order HeaderHistory 1278 record. The Receive RDC Reverse Shipment Data Program (317)can use the selected Order Header 1200 (or Order Header History 1278)data to update the first record written to the Item Return Detail table1268 and each subsequent Item Return Detail record 1268 written to thetable having the same Item Return Id, for example, as follows: RetailerOrder Number and Order Date/Time can be set to the values selected fromthe Order Header 1200 or Order Header History 1278 record.

After reading through and updating the Status on all the records in eachdata file, the Receive RDC Reverse Shipment Data Program (317) can sendthe data file back to the CDC server from which it was received. Uponreceiving each data file on the CDC server, a CDC Reverse ShipmentMaintenance Program (386) can read each record in the data file, verifythat its Status is a value such as “record received”, and delete itscorresponding record in the database, using its Item Return Id, CDCOutbound Package Id, or CDC Reverse Shipment Id. Item Return Header andItem Return Detail data files can be processed after both data fileshave been received. If the Receive RDC Reverse Shipment Data Program(317) is unable to write a new record to the ePD Shipping Application'sdatabase from the data file successfully, the Receive RDC ReverseShipment Data Program (317) can move the unsuccessfully written datafile record from the data file to an error file or table for later errorprocessing.

In a further aspect of the invention, RDC workers can use a Receive RDCReverse Shipment Program (319) of the ePD Shipping Application toreceive CDC reverse shipments into an origination RDC 1180-2, step 1408.The cargo cages and large item return/CDC outbound packages making upthe CDC reverse shipments can be physically moved from a trailerconveyor (204) onto a local market receiving dock conveyor (14) in amanner consistent with the way retailer shipments can be received into aRDC 1180-2. To start the Receive RDC Reverse Shipment Program (319) aRDC worker can select the Receive RDC Reverse Shipment Program's (319)start option on a workstation upon which it is located. After startingthe Receive RDC Reverse Shipment Program (319) a RDC worker can, forexample, scan their employee id card and the CDC reverse shipment labelon a CDC reverse shipment to trigger an update to the records related tothe CDC reverse shipment. The Receive RDC Reverse Shipment Program (319)can select the record on the CDC Reverse Shipment table 1274 having theCDC Reverse Shipment Id of the scanned CDC reverse shipment label andcan update it, for example, as follows: Status can be set to a valuesuch as “received”; Receiving Employee Id can be set to the value fromthe scanned employee id card; and CDC Reverse Shipment Arrival Date/Timecan be set to the current date/time. After updating the CDC ReverseShipment record 1274, the Receive RDC Reverse Shipment Program (319) canuse the CDC Reverse Shipment Id of that updated record 1274 to selectthe Item Return Header records 1266 and CDC Outbound Package records1270 having that CDC Reverse Shipment Id. The Receive RDC ReverseShipment Program (319) can update the Status on each selected ItemReturn Header record 1266 and CDC Outbound Package record 1270 to avalue such as “destination RDC” and “origination RDC” respectively.

Item return packages and CDC outbound packages can travel from a localmarket receiving dock conveyor (14) onto the inbound section of the RDCsort conveyor (16) and then onto the outbound section of the RDC sortconveyor (18). As the item return packages and CDC outbound packagesmove past the teams of workers performing the RDC sort process, step1112A (FIG. 13), those workers can look at the RDC Id on the labels ofthe item return packages and CDC outbound packages to identify the onesthat can be added to the RDC shipment they are currently building. TheRDC workers can, for example, pick the item return packages and CDCoutbound packages matching their RDC shipment, scan their labels usingthe stationary scanner located next to the side of the RDC shipping dockconveyor (22), and place them into a cargo cage on the shipping dockconveyor (22). As each item return package or CDC outbound package isscanned, the RDC Shipment Program (318) of the ePD Shipping Applicationcan write the RDC Shipment Id of the RDC shipment, being built on theshipping dock conveyor (22) associated with the stationary scanner used,to the RDC Shipment Id field on the Item Return Header record 1266 ofthe scanned item return package or the CDC Outbound Package record 1270of the scanned CDC outbound package. If a RDC worker scans an itemreturn package or CDC outbound package to start a new RDC shipment, theRDC Shipment Program (318) can create a new RDC Shipment record 1216 inthe same way that it can create a new record when scanning a case ofordered items, except Destination RDC Id on the new RDC Shipment record1216 can be set to the RDC Id value from the selected Item Return Headerrecord 1266 or CDC Outbound Package record 1270 instead of from aselected Case record 1208. Item return packages and CDC outboundpackages that are labeled with the current RDC Id can be picked from theoutbound section of the RDC sort conveyor (18) to the local market sortconveyor (24) by the same team of workers that is picking cases labeledwith the current RDC Id from the outbound section of the RDC sortconveyor (18) to the local market sort conveyor (24).

In another aspect of the invention item return packages and CDC outboundpackages can be shipped as part of a RDC shipment from an originationRDC 1180-2 to a destination RDC 1180-3 in step 1114A. A RDC shipmentarriving at its destination RDC 1180-3 may contain item return packagesand CDC outbound packages as well as cases of ordered items. The cargocages containing the item return packages and CDC outbound packages, aswell as the cases of ordered items, can be received into the destinationRDC 1180-3 in step 1116A, and can be moved from the trailer conveyor(204) to the RDC inbound receiving dock conveyor (32), to the unloadingsection (34), case diverting section (38), and local market connection(36) of the RDC inbound conveyor, and up onto the local market sortconveyor (24) in the same way as described in step 1116 (FIG. 1). Onedifference between step 1116A and step 1116, can be that item returnpackages and CDC outbound packages which were not described in step 1116can also be moved to the local market sort conveyor (24) along with thecases described in step 1116. In step 1116A, a RDC worker can performthe same actions as described in step 1116 to initiate the Receive RDCShipment Program (324), and the Receive RDC Shipment program (324) canperform the same steps, as detailed in step 1116, to update, forexample, the RDC Shipment record 1216 of the RDC shipment in thedatabase on the origination RDC's 1180-2 server and the RDC ShipmentReceiving record 1218 of the RDC shipment in the database on the currentdestination RDC's 1180-3 server. In addition to updating and moving allthe Case 1208, Order Header 1200, and Order Detail 1202 recordsassociated with the current RDC shipment from the database on theorigination RDC's 1180-2 server to the database on the destination RDC's11803 server, the Receive RDC Shipment Program (324) can also update andmove the Item Return Header 1266, Item Return Detail 1268, and CDCOutbound Package 1270 records associated with the current RDC shipmentfrom the database on the origination RDC's 1180-2 server to the databaseon the destination RDC's 1180-3 server. The Receive RDC Shipment program(324), running on the destination RDC's 1180-3 server, can use theremote connection that it established to the origination RDC's 1180-2server and the RDC Shipment Id, from the record on the RDC ShipmentReceiving table 1218 having the Trailer Id that was scanned when the RDCshipment was received, to select the Item Return Header records 1266 andCDC Outbound Package records 1270 from the origination RDC's 1180-2server having that RDC Shipment Id. The Receive RDC Shipment Program(324) can update the Status of the selected Item Return Header records1266 to a value such as “origination RDC” and the Status of the selectedCDC Outbound Package records 1270 to a value such as “destination RDC”.The Receive RDC Shipment Program (324) can use the Item Return Id's ofthe Item Return Header records 1266 to select their associated ItemReturn Detail records 1268. The Receive RDC Shipment program (324) canmove the selected Item Return Header 1266, Item Return Detail 1268, andCDC Outbound Package 1270 records from the database on the originationRDC's 1180-2 server to the database on the current destination RDC's1180-3 server. The RDC into which a RDC shipment arrives can be referredto as its destination RDC 1180-3, even though it may have been theorigination RDC for the items of a return item package and can bereflected as the “origination RDC” in the Status of item returnpackages.

The item return packages and CDC outbound packages that were moved tothe local market sort conveyor (24), during the RDC sort, step 1112A, orthe receipt of a RDC shipment, step 1116A, can move around on the localmarket sort conveyor (24) and pass by the RDC workers performing thelocal market sort, step 1118A. In addition to scanning case labels todetermine if a case should be picked from the local market sort conveyor(24) to the CDC sort conveyor (42) at which a RDC worker is stationed, aRDC worker can look at labels on item return packages and CDC outboundpackages to determine if they should pick them from the local marketsort conveyor (24) to their CDC sort conveyor (42). The worker can pickan item return package that has a Returns Local Market Id printed on itslabel that matches the local market id of their CDC sort conveyor (42).Additionally, the worker can also pick a CDC outbound package that has alocal market id, embedded in the CDC Id printed on its label, thatmatches the local market id of their CDC sort conveyor (42). In oneembodiment, item return packages and CDC outbound packages do not needto be scanned when picked from the local market sort conveyor (24).

In another aspect of the invention, a RDC worker performing the CDCsort, step 1120A, can scan the label of a CDC outbound package on theCDC sort conveyor (42) to determine if it is for the CDC 1190-3associated with the CDC packing station conveyor (44) for which the RDCworker is picking cases of ordered items. The CDC Sort Program (328) candetermine if the format of the data scanned from the label is for a caseor a CDC outbound package. If an item return package label gets scanned,the CDC Sort Program (328) can determine that the scanned data wasneither a Case Id nor a CDC Outbound Package Id and can, for example,sound an invalid pick tone. If a case label gets scanned, the CDC Sortprogram (328) can perform its processing as previously described in step1120. If a CDC outbound package label gets scanned, the CDC Sort program(328) can use, for example, the scanned CDC Outbound Package Id toselect the CDC Outbound Package record 1270 of the CDC outbound package,can validate its RDC Id and Local Market Id values, and can compare itsDestination CDC Id value against the CDC Id value of the currentinstance of the CDC Sort Program (328) (the instance associated with thecurrent CDC packing station conveyor (44)). The RDC Id and Local MarketId values on the selected CDC Outbound Package record 1270 can bevalidated by the CDC Sort Program (328) in the same way that the RDC Idand Local Market Id values on the Case record 1208 of a scanned case canbe validated. The worker who scanned the CDC outbound package canrespond to a validation error tone, for example, a double invalid pickwarning tone, from a scanned CDC outbound package in the same way theworker responds to a similar validation error tone from a scanned case.If the CDC Sort program (328) can determine that the CDC Id associatedwith the scanned CDC outbound package does not match the CDC Idassociated with the current instance of the CDC Sort Program (328), itcan indicate not to pick the scanned CDC outbound package, for example,by sounding an invalid pick tone. Upon hearing an invalid pick tone oranother indication not to pick a scanned CDC outbound package, a workercan allow a CDC outbound package or an item return package to pass bythem on the CDC sort conveyor (42). If the CDC Sort program (328)determines that the CDC Id associated with the scanned CDC outboundpackage matches the CDC Id associated with the current instance of theCDC Sort Program (328), it can indicate to pick the scanned CDC outboundpackage, for example, by sounding a pick confirmation tone. Upon hearinga pick confirmation tone or another indication to pick a scanned CDCoutbound package when scanning a CDC outbound package, the worker canpick the CDC outbound package from the CDC sort conveyor (42) and placeit on the CDC packing station conveyor (44) at which the worker isstationed.

In another aspect of the invention, CDC outbound packages can be addedto a delivery shipment of packages designated for a particular CDC orLDDH, step 1418. A RDC worker, creating an ePD delivery shipment on theCDC feed of a CDC package conveyor (47A) associated with a particularCDC 1190-3 or LDDH 1192-3 by scanning packages that were created at thecurrent destination RDC 1180-3 into cargo cages, step 1124, can alsopick and scan CDC outbound packages from the CDC packing stationconveyor (44) associated with that CDC 1190-3 or LDDH 1192-3 in step1418. The worker can place each CDC outbound package picked from the CDCpacking station conveyor (44) into a cargo cage of the current deliveryshipment that the worker is creating. Upon scanning a CDC outboundpackage label, the worker's instance of the Delivery Shipment CreationProgram (340) can, for example, recognize the format of the scannedvalue as a CDC Outbound Package Id instead of a Package Id, use thescanned CDC Outbound Package Id to select the appropriate CDC OutboundPackage record 1270, display the Package Size of the selected record1270 on the workstation running the Delivery Shipment Creation Program(340), and prompt the worker to confirm or override the displayedPackage Size. After the worker confirms or overrides the displayedPackage Size, the Delivery Shipment Creation Program (340) can update,for example, the selected CDC Outbound Package record 1270 by settingits Status to a value such as “delivery shipment” and writing theDelivery Shipment Id, of the current delivery shipment being created, toits Delivery Shipment Id field. If the worker overrode the displayedPackage Size value instead of confirming it, the Delivery ShipmentCreation program (340) can also update the Package Size on the selectedrecord 1270 to the value entered by the worker and can write data valuesfrom the selected record 1270 to a table or file that can be used tocreate an exception report of CDC outbound packages which have had theirPackage Size overridden. The data fields which can be written to thetable or file can include, but are not limited to the CDC OutboundPackage Id, Shipping Customer Id, Delivery Type, original Package Size,overriding Package Size, and Employee Id of the worker creating thedelivery shipment (this value is not read from the selected CDC OutboundPackage record 1270, but can be scanned into the Delivery ShipmentCreation program (340)). An exception report of CDC outbound packages,which have had their Package Size overridden, can later be used formaking billing adjustments to the package senders of the CDC outboundpackages listed on that exception report.

After a CDC outbound package has been added to a delivery shipment instep 1418, the CDC outbound packages can be shipped in bulk, as in step1420, to the CDC 1190-3. The method can follow the same physicalmovement from the CDC feed of a CDC package conveyor (47A) all the wayto being retrieved from a SBU bin at a CDC 1190-3 by its recipient instep 1150A. With reference to FIG. 13, these steps can be similar tothose previously described for the CDC in FIG. 1. Hence, step 1140 canbe equivalent to 1140A; step 1142 can be equivalent to step 1142A; step1144 can be equivalent to step 1144A; step 1148 can be equivalent tostep 1148A; and step 1150 can be equivalent to step 1150A. The programsused to reserve SBU bins, make adjustments to delivery shipments, andmake SBU configuration adjustments for the packages of a deliveryshipment can account for CDC outbound packages in the same way as theyaccount for packages created in a destination RDC 1180-3. The programsused to load packages into SBU bins, notify recipients that packageshave been delivered to a CDC 1190-3, and unload packages from SBU binscan process the movement of CDC outbound packages in the same way thatthey process the movement of packages created in a destination RDC1180-3, except that a CDC Outbound Package Id can be written to thePackage Id field on a Bin Inventory record 1300 instead of a Package Id,and updates can be made to the Status, Notification Date/Time, andPickup Date/Time on a CDC Outbound Package record 1270 associated with aCDC outbound package instead of the Package 1234, Order Detail 1202, andOrder Header 1200 records associated with a package (the programs canupdate the Status of a CDC Outbound Package record 1270 to the samevalues to which the Status of an Order Detail record 1202 can beupdated). CDC outbound packages which can be added to delivery shipmentsbound for an LDDH 1192-3 instead of a CDC 1190-3 can be physically movedand logically tracked in the same way as packages created in adestination RDC 1180-3, except that data can be read and updated fromCDC Outbound Package records 1270 instead of Order Header 1200, OrderDetail 1202, and Package 1234 records. The billing process, step 1138(FIG. 1), that follows the notification of delivery of ordered items toa CDC 1190-3 or the actual delivery of ordered items to a specificaddress can be unnecessary after the delivery of CDC outbound packages,because the package sender had already been charged at the time the CDCoutbound package was sent. If the original shipping charge for a CDCoutbound package was based upon a Package Size that was later overriddenby a shipper, the package sender can be billed for additional shippingcosts or refunded for an excessive shipping payment. Billing orrefunding package senders for differences in shipping costs due to anincorrect estimation of Package Size can be facilitated by using anexception report of CDC outbound packages which have had their PackageSize overridden. Following step 1418, CDC outbound packages bound for aCDC 1190-3 can be referred to collectively, along with packages createdat a destination RDC 1180-3, as bulk delivered packages, since they willboth be treated the same as they are delivered in bulk to a CDC 1190-3and loaded into SBU bins.

In a further aspect of the invention, RDC returns shipments can becreated by grouping item return packages by the retailer returnsfacilities for which they are bound in step 1410. One or more RDCworkers creating RDC returns shipments bound for the returns facilitiesof retailers within a local market can be stationed at some point alonga CDC sort conveyor (42) associated with that local market. The workerscan, for example, wear hands-free scanners that can communicate with aworkstation, which can run an instance of the RDC Returns ShipmentCreation Program (341) of the ePD Delivery Application. A RDC worker canstart the RDC Returns Shipment Creation Program (341) on the workstationand can scan their employee id card, before adding item return packagesto a RDC returns shipment. Other RDC workers with hands-free scannerscommunicating with that workstation can scan their employee id cards tosign on to the RDC Returns Shipment Creation Program (341) and can workas a team with the worker who started the RDC Returns Shipment CreationProgram (341), to add item return packages to RDC returns shipments. Asitem return packages move past them on the CDC sort conveyor (42), theycan scan the item return labels to pick them for the RDC returnsshipments they are creating. If a CDC outbound package gets scannedinstead of an item return package, the RDC Returns Shipment CreationProgram (341) can, for example, sound an invalid pick tone and display amessage on the workstation to indicate that the scanned package shouldnot be picked. When a worker creating RDC returns shipments scans anitem return package, the RDC Returns Shipment Creation Program (341) canselect an Item Return Header record 1266 using the Item Return Id valuefrom the scanned item return package label. With reference to FIG. 9G,the RDC Returns Shipment Creation program (341) can use the ePD RetailerId on the selected Item Return Header record 1266 to select a recordfrom a RDC Returns Shipment table 1276 having that ePD Retailer Id and aStatus value such as “open”. If the RDC Returns Shipment CreationProgram (341) is able to select a record 1276 with the ePD Retailer Idof the scanned item return package and a Status such as “open”, it can,for example, sound a pick confirmation tone, and display a message toindicate that the item return package should be picked for the RDCreturns shipment of the retailer associated with the scanned item returnpackage (the retailer having an ePD Retailer Id embedded in the ItemReturn Id of the scanned item return package label). The worker can, forexample, pick the item return package from the CDC sort conveyor (42),scan the RDC returns shipment label of the RDC returns shipment for theretailer associated with the picked item return package (on a labelplate on one of its cargo cages), and place the item return package intoone of the cargo cages of that RDC returns shipment. The RDC ReturnsShipment Creation Program (341) can validate that the RDC ReturnsShipment Id on the scanned RDC returns shipment label matches the RDCReturns Shipment Id of the selected RDC Returns Shipment record 1276. Ifthe RDC Returns Shipment Id on the scanned RDC returns shipment labelpasses validation, the RDC Returns Shipment Creation Program (341) canupdate the selected Item Return Header record 1266, for example, asfollows: Status can be set to a value such as “RDC returns shipment”;and RDC Returns Shipment Id can be set to the value of the selected RDCReturns Shipment record 1276. The RDC Returns Shipment Creation Program(341) can also compare the Employee Id of the worker who scanned theitem return package against the values of the RDC employee id fields(RDC Employee Id #1 through RDC Employee Id #5) on the selected RDCReturns Shipment record 1276 and can add the worker's Employee Id to thefirst available RDC Employee Id field if it is not already on the record1276. After making the record updates, the RDC Returns Shipment CreationProgram (341) can, for example, sound a confirmation tone and display amessage to confirm that the scanned item return package was added to thescanned RDC returns shipment successfully. If the scanned RDC returnsshipment label does not pass validation, the RDC Returns ShipmentCreation Program (341) can, for example, sound an invalid warning tone,and display a message to alert the worker that a RDC returns shipmentlabel of a different retailer's RDC returns shipment was scanned and toindicate the ePD Retailer Id of the scanned item return package.

In a further aspect of the invention, the instance of the RDC ReturnsShipment Creation Program (341) that the workers can be logged into cantrack and differentiate between the scanning actions of one worker fromthe scanning actions of another by associating a unique identifier ofthe scanning device used by each worker with the data scanned by thatdevice. For example, if the first scan registered by the RDC ReturnsShipment Creation Program (341) was from a first worker scanning an itemreturn package, the second scan registered by the RDC Returns ShipmentCreation Program (341) was from a second worker scanning an item returnpackage, and the third scan registered by the RDC Returns ShipmentCreation Program (341) was from the first worker scanning a RDC returnsshipment label, the RDC Returns Shipment Creation Program (341) would beable to differentiate between the scans of the two different devices andwould validate the third scan against the first scan, since that was thenext sequential scan by that scanning device.

If the RDC Returns Shipment Creation Program (341) was unable to find arecord with the ePD Retailer Id of the scanned item return package and aStatus value such as “open”, when the item return package label wasscanned, the RDC Returns Shipment Creation Program (341) can, forexample, create a new RDC Returns Shipment record 1276, print a RDCreturns shipment label, sound a pick confirmation tone, and display amessage on the workstation's display monitor indicating that a new RDCreturns shipment should be created for the scanned item return package.The new RDC Returns Shipment record 1276 can be created, for example, asfollows: RDC Returns Shipment Id can be created by concatenating the RDCId of the current destination RDC 1180-3+the ePD Retailer Id from theselected Item Return Header record 1266+the current date+a three digitsequential number; Status can be set to a value such as “open”; ePDShipper Id can be set to the value of the shipper operating the currentdestination RDC 1180-3; ePD Retailer Id can be set to the value from theselected Item Return Header record 1266; RDC Id can be set to the valueof the current destination RDC 1180-3; Temperature Code can be set to avalue such as “standard” (non-standard temperature items can be returnedvia a more direct route to a retailer's returns facility); and RDCEmployee Id #1 can be set to the Employee Id of the worker who scannedthe item return package (which can be associated with the uniqueidentifier of the scanning device used to scan the item return package).

The RDC returns shipment label printed by the RDC Returns ShipmentCreation Program (341) can include, but is not limited to the followinginformation: RDC Returns Shipment Id in both a readable format and abarcode format. The worker who scanned the item return package whichinitiated the new RDC returns shipment can take the label from theworkstation's label printer, affix it to a label plate, place the labelplate in the label plate holder of an empty cargo cage, place thescanned item return package into the cargo cage, and scan the new labelto add the scanned item return package to the new RDC returns shipment.

Any one of the workers creating RDC returns shipments for the retailersof a particular local market can close a RDC returns shipment, byselecting a program option of the RDC Returns Shipment Creation Program(341), such as the “close shipment” option, and then scanning the RDCreturns shipment label of the RDC returns shipment to be closed. When aprogram option of the RDC Returns Shipment Creation Program (341) suchas the “close shipment” option is selected, the RDC Returns ShipmentCreation Program (341) can update the Status of the RDC Returns Shipmentrecord 1276 to a value such as “closed”. Because RDC returns shipmentcan be shipped with other RDC returns shipments or delivery shipmentsbound for the same local market, a worker can close a RDC returnsshipment when it is the size of a full-trailer-load or at any time whenit is smaller than the size of a full-trailer-load. A RDC returnsshipment can be built on top of a RDC returns shipment conveyor (62),next to the CDC sort conveyor (42) of the local market for which it isbound, or it can be built near that RDC returns shipment conveyor (62)and then positioned on that RDC returns shipment conveyor (62) withother closed RDC returns shipments, once it has been closed. RDC returnsshipments can be moved from a RDC returns shipment conveyor (62) to apackage conveyor (46A or 46B) in a coordinated manner to position themnear one or more delivery shipments from the same local market to createa full-trailer-load.

In another aspect of the invention, RDC returns shipments can be movedthrough the destination RDC 1180-3 and loaded onto tractor-trailers (200& 202) leaving the destination RDC 1180-3 for a local market in the samemanner as described for (and possibly along side of) delivery shipmentscontaining packages of ordered items and/or CDC outbound packages. Step1412 shows this shipment of the item return packages to retailer returnsfacility. One difference in the process of loading a RDC returnsshipment onto a tractor-trailer (200 & 202) as compared to a deliveryshipment can be that the Delivery Shipment Program (342) can verify andreserve available bin space for the packages and CDC outbound packagesof a delivery shipment, but the Delivery Shipment Program (342) does notneed to do so for the item return packages of a RDC returns shipment. Ifa RDC returns shipment label is scanned by a worker running the DeliveryShipment Program (342), the Delivery Shipment Program (342) can selectthe RDC Returns Shipment record 1276 having the scanned RDC ReturnsShipment Id and can update it, for example, as follows: Status can beset to a value such as “reported”; Trailer Loading Employee Id can beset to the value of the employee id card scanned by the worker runningthe Delivery Shipment Program (342); Trailer Id can be updated to thevalue of the scanned Trailer Id barcode; and RDC Returns ShipmentLoading Date/Time can be set to the current date/time. The DeliveryShipment Program (342) can store the RDC Returns Shipment Id from thescanned RDC returns shipment label to be printed in both a readabledescription and a barcode format on the Delivery Shipments Report whenit is printed. The Delivery Shipment Program (342) can use the ePDRetailer Id on the selected RDC Returns Shipment record 1276 to selectthe retailer's record from the Retailer table 1246 and can store the ePDRetailer Description, Returns Facility Id, and the address of theretailer's returns facility (Returns Address 1, Returns Address 2,Returns City, Returns State, Returns Zip) from the selected Retailerrecord 1246 to be printed on the Delivery Shipments Report when it isprinted. After a RDC worker scans all the delivery shipments and RDCreturns shipments of the full-trailer-load and selects a program optionto end the Delivery Shipment Program (342) and print the DeliveryShipments Report, the delivery shipments and RDC returns shipments canbe loaded onto the tractor-trailer (200 & 202) as previously describedin this disclosure.

In yet a further aspect of the invention, a RDC Returns Shipment DataTransfer Program (343) can run as a service on the destination RDC's1180-3 server to monitor the RDC Returns Shipment table 1276, searchingfor records with a Status value such as “reported”. The RDC ReturnsShipment Data Transfer Program (343) can select RDC Returns Shipmentrecords 1276 having a Status value such as “reported”, update the Statusof each selected record to a value such as “in-transit”, and use the RDCReturns Shipment Id of each selected record 1276 to select Item ReturnHeader records 1266 having that RDC Returns Shipment Id. The RDC ReturnsShipment Data Transfer Program (343) can write the selected Item ReturnHeader records 1266 into a new Retailer Returns Header data file, andcan use the Item Return Id's of the selected Item Return Header records1266 to select their associated Item Return Detail records 1268. The RDCReturns Shipment Data Transfer Program (343) can write the selected ItemReturn Detail records 1268 into a new Retailer Returns Detail data file.The RDC Returns Shipment Data Transfer Program (343) can write the ePDRetailer Id and RDC Returns Shipment Id of each selected RDC ReturnsShipment record 1276 and the current date/time to the file header ofboth data files created for that RDC returns shipment. The RDC ReturnsShipment Data Transfer Program (343) can also use the ePD Retailer Id ofeach selected RDC Returns Shipment record 1276 to select that retailer'srecord from the Retailer table 1246 and can, for example, use theinformation in its Connection Script field to connect to the retailer'sserver and transfer the Retailer Returns Header and Retailer ReturnsDetail data files from the destination RDC's 11803 server to theretailer's server. A Receive RDC Returns Shipment Data Program (311) ofthe retailer's instance of the ePD Shipping Application can run as aservice on a workstation or server at a retailer's returns facility toread Retailer Returns Header and Retailer Returns Detail data files asthey are received and can create Item Return Header 1266 and Item ReturnDetail 1268 records on the database of the retailer's instance of theePD Shipping Application. In step 1414, workers at a retailer returnsprocessing facility can receive and process return item packages. One ofthe workers at a retailer's returns facility can initiate the ReceiveRDC Returns Shipment Program (313) of the retailer's instance of the ePDShipping Application on a workstation, can scan their employee id card,and can then scan the RDC returns shipment label on a RDC returnsshipment arriving at the returns facility to receive it from a shipper.The Receive RDC Returns Shipment Program (313) can use the RDC ReturnsShipment Id to select and update, for example, the Item Return Headerrecords 1266 associated with the received RDC returns shipment, forexample, as follows: Status can be set to a value such as “returned”;and Item Return Retailer Receipt Date/Time can be set to the currentdate/time. After updating the Item Return Header records 1266, theReceive RDC Returns Shipment Program (313) can create a simple RDCReturns Shipment Receipt Confirmation data file containing the RDCReturns Shipment Id of the received RDC returns shipment, the EmployeeId value scanned from the retailer worker's employee id card, and theItem Return Retailer Receipt Date/Time. The Receive RDC Returns ShipmentProgram (313) can use the RDC Id from one of the Item Return Headerrecords 1266 associated with the current RDC returns shipment (each ItemReturn Header record 1266 associated with the current RDC returnsshipment should have the same RDC Id) to send the RDC Returns ShipmentReceipt Confirmation data file to the destination RDC 1180-3 from whichthe RDC returns shipment originated.

Upon receiving a RDC Returns Shipment Receipt Confirmation data filefrom a retailer's returns facility, a RDC Returns Shipment UpdateProgram (388) of the shipper's instance of the ePD Delivery Applicationcan use the RDC Returns Shipment Id in the data file to select the RDCReturns Shipment record 1276 and all of the Item Return Header records1266 associated with the RDC returns shipment. The RDC Returns ShipmentUpdate Program (388) can update the selected RDC Returns Shipmentrecord, for example, as follows: Status can be set to a value such as“received”; Retailer Employee Id can be set to the Employee Id in thereceived data file; and RDC Returns Shipment Arrival Date/Time can beset to the Item Return Retailer Receipt Date/Time in the received datafile. The RDC Returns Shipment Update Program (388) can update, forexample, the Status to a value such as “returned” on each selected ItemReturn Header record 1266. The data on the Item Return Header 1266 andItem Return Detail records 1268 with a Status value such as “returned”can be used by a shipper, in step 1416, to bill retailers for deliveringitem return packages. The Status of the Item Return Header record 1266can be updated to a value such as “billed” after the billing step iscomplete. For example, shippers can bill retailers for each item returnpackage or for the total number of items returned by using the datacontained in the Item Return Header 1266 and Item Return Detail 1268records associated with a delivered (returned) item return package.

In another embodiment of the invention, various entities can coordinatewith each other to perform each of the different steps within the ePDDelivery Process. For example, a retailer can capture orders; a productfulfillment concern can pick cases of ordered items and prepare them forshipment to an origination RDC; a retailer, shipper, or otherorganization can transport cases of ordered items to an origination RDC;a separate organization can operate an origination RDC and forward casesof items to a destination RDC operated by another organization; bulkdelivered packages can be delivered to CDC's by a shipper; a separateorganization can operate a CDC; and yet another organization can billretailers, customers or recipients for orders delivered to CDC's.Without departing from the spirit of the invention, there can be manydifferent combinations of the various entities being responsible for thedifferent steps within the ePD Delivery Process, from having oneorganization do everything to having a different organizationresponsible for each step.

In another aspect of the invention, a shipper can operate CDC'sexclusively for the bulk delivered packages it is delivering. Thesecured backroom area (154) of a CDC may not require the holding cages(134) since all bulk delivered packages which can be left in thebackroom area (154) can be for the same shipper, and only the workers ofthat shipper can have access to that CDC's backroom area (154). Eventhough only one shipper can be sending packages to that CDC, the tables,data views, and programs that enable the functionality of reserving SBUbins within a CDC can still function to reserve bins for the bulkdelivered packages or CDC outbound packages of each delivery shipment inthe order in which they are shipped. This can allow a shipper to makedelivery shipment adjustments to ensure that a delivery shipment is notsent to a CDC, when that CDC does not have the capacity to accept all ofthe bulk delivered packages and/or CDC outbound packages of thatdelivery shipment.

In another embodiment of the invention, a customer order taken by aretailer can be fulfilled from more than one retailer fulfillment site.A retailer (or other equivalent business that can accept and fulfillorders) can accept an order from a customer for various items that itsells. The items to fill that order can be shipped in cases, organizedby a common item identifier, from more than one fulfillment site to oneor more origination RDC's to fill that order. One or more of thefulfillment sites can be owned and/or operated by the retailer acceptingthe order, or the fulfillment sites can be owned and/or operated by amanufacturer, another retailer, or another entity with which theretailer has contracted to fulfill its orders. In this embodiment,orders can be captured and recorded in Order Header 1200 and OrderDetail records 1202 by the retailer in the same nature as described inthe embodiment depicted in FIG. 2, except for the following differencesrelated to the structure and data contained on the Order Header 1200 andOrder Detail 1202 tables to enable this embodiment: the ePD Retailer Idfield can be included on the Order Detail record 1202 instead of theOrder Header record 1200 to allow for more than one ePD Retailer Id tobe associated with an order, and an Order Processing Retailer Id fieldcan be included on the Order Header record 1200 to capture theidentifier associated with the one retailer having overallresponsibility for that order. The ePD Retailer Id can identify theretailer fulfillment site (or other equivalent business' fulfillmentsite) from which the ordered items of a particular Order Detail record1202 can be sourced. The Order Processing Retailer Id can identify theretailer, manufacturer, or other entity that can capture a customer'sorder in an Order Header record 1200 and one or more Order Detailrecords 1202. After capturing an order, the database of the instance ofthe ePD Shipping Application being run at each fulfillment siteidentified by an ePD Retailer Id that is listed on one of the OrderDetail records 1202 of an order can be sent a copy of that order's OrderHeader record 1200 and a copy of each Order Detail record 1202 havingthe ePD Retailer Id associated with that fulfillment site. The copies ofthe appropriate Order Header 1200 and Order Detail 1202 records can besent at the time that the retailer receives the order from the customeror at a later interval via a batch process. After receiving the copiesof the Order Header 1200 and Order Detail 1202 records related to anorder, a fulfillment site can pick cases of items to meet the orders itreceives in the same manner as described in the embodiment depicted byFIG. 2. The cases of ordered items can be sent from each retailerfulfillment site to its associated RDC (depending upon the shipper beingused for the order), and depending upon the location of the differentretailer fulfillment sites sourcing an order, the items of that ordermay initially be received into several different origination RDC's.Processing steps consistent with the embodiment described for FIG. 2,can be performed to sort, transport, combine into packages, and deliverpackages of the ordered items to a CDC in bulk or to customer-specifiedaddress, regardless of from how many retailer fulfillment sites thoseordered items originated. The retailer responsible for the entire ordercan be tracked and billed using the Order Processing Retailer Id on theOrder Header record 1200.

In yet another embodiment of the invention, there can be retailerscreating bulk delivered packages at their fulfillment sites and shippingthose retailer-created bulk delivered packages to a RDC. Retailers canpick items and create bulk delivered packages at their fulfillment sitesto fill each customer order. Customer orders can either be pickedindividually or batch picked and sorted at a packing station to createbulk delivered packages to fill customer orders. A retailer can, forexample, print a packing list and a package label for each customerorder, place the packing list inside the bulk delivered package, andaffix the package label on the outside of the bulk delivered package.The package label can contain a Package Id in barcode format and a RDCId and CDC Id in readable format. The bulk delivered packages created atthe retailer fulfillment site can be shipped to a RDC by the retailer ora shipper on a tractor-trailer or other cargo carrying transport forfurther processing. Retailer-created bulk delivered packages labeledwith a RDC Id different than the RDC which received the bulk deliveredpackages from the retailer fulfillment site (the origination RDC) can besorted by RDC Id (in the RDC sort process) at the origination RDC,forwarded to the appropriate destination RDC as part of a RDC shipment,and shipped out of the destination RDC to a CDC or LDDH as part of adelivery shipment. Retailer-created bulk delivered packages labeled withthe RDC Id of the origination RDC can pass through the RDC sort at theorigination RDC, move into the local market sort, be picked directlyfrom the CDC sort conveyor (42) into a delivery shipment, and be shippedout of the RDC as a bulk delivered package to a CDC or LDDH in one ofthe local markets served by that RDC. In a further aspect of theinvention, the retailer-created bulk delivered packages, that have a CDCId, which is in the same local market as the retailer fulfillment sitein which that bulk delivered package was created, can be grouped by CDCId and shipped directly to a CDC or LDDH within that local market by theretailer or a shipper. In this embodiment, all other retailer-createdbulk delivered packages can be shipped to a RDC. In a further aspect ofthe invention, the retailer-created bulk delivered packages having anyCDC Id can be grouped by CDC Id at a retailer fulfillment site andshipped directly to the CDC or LDDH to which it should be deliveredwithout first being shipped to a RDC.

The invention can further include more than one retailer-created bulkdelivered package that can be combined together to create fewer, largerbulk delivered packages. Retailers can create bulk delivered packages attheir fulfillment sites and send them on retailer shipments to anorigination RDC. The processing at an origination RDC can includesorting the retailer-created bulk delivered packages by RDC Id andforwarding them to their destination RDC in RDC shipments. Theprocessing at a destination RDC can include sorting the retailer-createdbulk delivered packages by CDC Id, and then by Customer Id within thegroup of retailer-created bulk delivered packages organized by CDC Id.Once grouped by Customer Id within a CDC Id, multiple retailer-createdbulk delivered packages can be combined into a larger package to bedelivered for a package recipient at a CDC or a customer specifiedaddress. This embodiment can require an addition level of sorting, butcan decrease the number of bulk delivered packages that need to behandled in delivering customer orders.

In a further embodiment of the invention, the programs used to sortcases and create bulk delivered packages at a RDC can function withoutusing Temperature Code. In this embodiment, Temperature Code may noteven be tracked on the tables and data views upon which it is tracked inthe main embodiment, and the Package Creation Program (330) can createbulk delivered packages by grouping picked items into bulk deliveredpackages by CDC Id-Customer Id combination, instead of by CDCId-Customer Id-Temperature Code combination.

Another aspect of the invention can include creating retailer-specificbulk delivered packages at a destination RDC. Retailers can ship casesof ordered items to an origination RDC to create bulk delivered packagesat a destination RDC as described in the main embodiment. The receiving,inter-RDC shipping, and sorting processes described in the mainembodiment can occur in this embodiment, except that the PackageCreation Program (330) can create retailer-specific bulk deliveredpackages by grouping picked items into packages by CDC Id-CustomerId-Temperature Code-ePD Retailer Id combination, instead of by CDCId-Customer Id-Temperature Code combination. If Temperature Code is notan active factor used to segregate items into bulk delivered packagesfor recipients, then CDC Id-Customer Id-ePD Retailer Id combination canbe used instead of using CDC Id-Customer Id combination. By adding ePDRetailer Id to the Package Creation Program's (330) criteria fordetermining whether to direct a worker to pick an item for a bulkdelivered package, a different bulk delivered package can be created tohold the items ordered from each retailer, to be delivered to a packagerecipient at a CDC or customer specified location. Each bulk deliveredpackage can contain ordered items from only one retailer.

In yet a further embodiment of the invention, bulk delivered packagescan be sent from more than one RDC to a CDC. This can increase thenumber of ordered items that can be shipped to a CDC from an originationRDC, rather than being shipped as part of a RDC shipment to adestination RDC, before being shipped to a CDC. By eliminating the needto transport some items on a RDC shipment, this embodiment could lowerthe overall shipping cost on some orders. Enabling this embodiment canbe more complex than the main embodiment described, however, as the PickList Report Program (310) would need to be able to determine if theshipper's origination RDC is a RDC which delivers to the CDC or LDDHassociated with an order, and if it is not, the Pick List Report Program(310) would need to be able to determine which RDC Id, of more than onepossible RDC, to write to an Order Header record 1200. To enable thisembodiment, a decision table or a set of processing rules could becreated for and utilized by the Pick List Report Program (310) tocompare one of the possible RDC Id's against the RDC Id of the shipper'sorigination RDC for that particular retailer fulfillment site. Inanother aspect of the invention, a shipper can operate a distributionnetwork in which one centralized RDC can be utilized to receive allretailer shipments and CDC reverse shipments and create bulk deliveredpackages and delivery shipments to be shipped out to all CDC's andLDDH's. This embodiment can be essentially the same as the mainembodiment described in this disclosure, except that a shipper operatesonly one RDC, a RDC sort sub-process is not needed, RDC shipments do notneed to be created, and all cases, CDC outbound packages, and itemreturn packages can move directly into the local market sort sub-processat that shipper's one central RDC following receipt. Assigning a RDC Idto orders for a shipper operating only one RDC can also be simplified byhaving the programs, which assign a RDC Id to the different records thatcontain a RDC Id, default to the one RDC Id for that shipper.

In a further embodiment, the local market sort step of the ePD deliveryprocess can be bypassed. A RDC can contain only one CDC sort conveyor,which can be located adjacent to all the CDC packing station conveyors(44) in that RDC. Cases of ordered items, CDC outbound packages, anditem return packages, having the RDC Id of the RDC in which they arelocated, can flow from a RDC sort conveyor (18) or a RDC inboundconveyor (34) directly onto one single CDC sort conveyor, which can belocated adjacent to all the CDC packing station conveyors (44) withinthat RDC to allow workers performing the CDC sort to scan and pick thosecases and CDC outbound packages onto their CDC packing station conveyors(44). RDC workers creating RDC returns shipments can be grouped by localmarket or by groups of retailers and stationed along the one CDC sortconveyor at different points to scan and pick item return packages fromthe one CDC sort conveyor. This can result in a cost savings associatedwith not performing the local market sort step, but the CDC sort stepmay be less efficient and more costly.

Other aspects of the invention can include using multiple local marketsort conveyors (24) to perform the local market sort step of the ePDdelivery process. In this embodiment, a RDC can have more than one localmarket sort conveyor (not shown as constructed for this embodiment).Cases of ordered items, CDC outbound packages, and item return packages(having the RDC Id of the RDC in which they are located) can flow fromthe RDC sort conveyor (18) and the RDC inbound conveyor (34) onto one ofthe multiple local market sort conveyors. Each local market sortconveyor can move the cases and packages past the CDC sort conveyors(42), which can each represent a different local market. CDC sortconveyors (42) can be grouped together around one of the multiple localmarket sort conveyors randomly, by geographical location, or by someother logic. RDC workers performing the RDC sort for the current RDCwould need to be able to determine to which local market sort conveyorto move the cases and packages. This could be accomplished by scanningthe case or package label or reading the Local Market Id embedded in theCDC Id printed on the labels of CDC outbound packages and item returnpackages. A new RDC activity would need to be performed to enable thisembodiment, requiring one or more workers to scan and pick cases fromthe RDC inbound conveyor (34), and to scan and pick or look at thelabels on CDC outbound packages and item return packages and pick themonto one of the multiple local market sort conveyors. In another aspectof the invention, when cases, CDC outbound packages, and item returnpackages can be separated by RDC Id during the RDC sort at theirorigination RDC, they can be grouped together into shipments specific tothe local market sort conveyors of their destination RDC. The RDCShipment Program (318) can have the ability to facilitate the creationof an RDC shipment for a subset of the local markets served by a RDC.

In a further embodiment of the invention, the RDC Id can be located onthe Order Detail records 1202 instead of Order Header records 1200, oralternately, on both records. This embodiment can reduce or eliminatethe number of times that programs need to use the Order Id on an OrderDetail record 1202 to select the Order Header record 1200 associatedwith an order to determine the RDC Id of that order.

Further aspects of the invention can include different methods of datatransfer that can be utilized to copy or move data between twodatabases. Data records can be copied or moved from a table in onedatabase to a table, having the same data structure (and in manysituations the same name), in another database. The two databasesinvolved in a data transfer can be located on the same server or on aplurality of servers. Different methods of data transfer can be employedwithin the ePD Delivery Process for transferring data from a table in adatabase on one server to a table in a database on another server. Thedata transfer opportunities can include, but are not limited to theprograms that copy or move data between the tables of the database on aretailer server and a RDC server, between two different RDC servers, orbetween a RDC server and a CDC server. The differences in the method ofdata transfer can include copying data instead of moving data, movingdata instead of copying data, and whether a program “pushes” the data toanother program (which can be initiated by the program transferring thedata) or “pulls” the data from another program (which can be initiatedby the program receiving the data). For example, the Retailer ShipmentProgram (312), running on a retailer server, can establish a connectionto the server of the RDC to which a retailer shipment is headed, at thetime the retailer shipment is loaded onto an outbound trailer. TheRetailer Shipment Program (312) can move the Retailer Shipment record1212 associated with that retailer shipment to the Retailer Shipmenttable 1212 in the RDC server's database. In this exemplary embodiment,the Retailer Shipment Program (312) can also select the Case 1208 andOrder Detail 1202 records having the Retailer Shipment Id of theretailer shipment and can move those records and the Order Header 1200records associated with the selected Order Detail records 1202 to thecorresponding tables in the database on the RDC server. Thus, prior tothe arrival of that retailer shipment, the database of the RDC to whichthe retailer shipment is being sent would have a Retailer Shipmentrecord 1212 and one or more Case 1208, Order Detail 1202, and OrderHeader 1200 records associated with that retailer shipment. The Statuson those records would reflect that the retailer shipment is still intransit and has not yet been received—the Status field on those records(on the RDC server's database), in the exemplary embodiment, would havethe same values that the Status field on those records (on the retailerserver's database) would have in the main embodiment. When the retailershipment is received into the RDC, the Status values of the RetailerShipment 1212, Case 1208, Order Detail 1202, and Order Header 1200records can be updated to reflect that the retailer shipment has beenreceived (the values in the Status fields can be set to the same values,in the exemplary embodiment, that those records would have in the Statusfield, in the main embodiment, after the retailer shipment had beenreceived). Although the method and timing of when the data can bewritten to the RDC server can be different in this exemplary embodiment,the material result remains the same, so that the records can be in thedatabase of the RDC server with the appropriate values. Since therecords were moved instead of copied, the retailer database does notcontain a copy of the records.

In still a further embodiment of the invention, different means can beused to transfer data from one database to another including, but notlimited to remote data connections and file transfer. A program of anapplication that can be connected to one database can establish a remotedata connection to a different database, on a different server, to copyor move data from or to that database. Different types of remote dataconnections can be established between the programs and/or databases ona first server and the programs and/or databases on a second serverincluding, but not limited to the following: a dedicated networkconnection can be continuously available between the two servers; ahigh-speed or standard-speed direct dial-up connection can beestablished; and a high-speed or standard-speed connection can beestablished through an intermediary service provider. In one aspect ofthe invention, a first program can create and send one or more filescontaining data from a first database on a first server (or aworkstation connected to the first server) to a second server (or aworkstation connected to the second server).

A second program can later read the files and write the data containedtherein to a second database on the second server to complete the actionof copying or moving data from the first database to the seconddatabase. The program initiating the creation of the file can be on thefirst server or the second server. There can also be a separate programor service to initiate the transfer of the files from one server toanother, instead of having one program create and send the files. Thetiming of the file transfer can be immediate (real-time) or scheduled(batch) for a specified future time or at a regular interval. The filescan be sent over a private network, a public network, or the internet.Varying file encryption/data encryption standards can be used to protectthe data being sent in the files.

In yet another embodiment of the invention, a wireless networkarchitecture can be used at retailer fulfillment sites, RDC's, and/orCDC's to connect workstations to servers, servers to other servers,workstations and/or servers to various types of scanning devices, andworkstations and/or servers to automated equipment and other peripheraldevices including, but not limited to conveyors, printers, CDC packingstations (45), digital video cameras, electronically locking doors, andSBU's. The type of technology enabling a wireless network at a retailerfulfillment site, RDC, and/or CDC can be radio frequency (RF), home RF,Bluetooth, WAP, and/or any other suitable type of wireless networkingtechnology. An in-building wireless system employing, for example, TDMA,CDMA, AMPS or GSM can be used. One example of using a wireless networkarchitecture can involve using a RF system in a CDC. In this exemplaryembodiment, a CDC worker can use a hands-free scanner connected to theCDC server of a CDC via a RF system. The worker can scan their employeeid card to log in to the Loading Program (356) and a SBU label on theoutside of one of the SBU's. SBU's can have label(s) on their exteriorwith their SBU Id in barcode format, and scanning the label on a SBU(after having scanned an employee id card) can trigger the same actionsthat scanning an employee id card, with a scanner that is plugged into aSBU, does in the main embodiment—the Loading Program (356) can move therevolving bins to position the closest available bin in the loadingposition, unlock the SBU's bin doors, and associate the Employee Id thatwas previously scanned with any future loading actions performed on thatSBU. Those main actions can be in addition to the validation, tableupdates, and other actions that the Loading Program (356) can perform.The worker can then scan package labels followed by bin door labels asthe worker loads bulk delivered packages into that SBU. The LoadingProgram (356) can function in the same way in response to the scans of ascanning device connected via a wireless network in this embodiment, asit would to the scans of a physically connected scanning device in themain embodiment. The wireless aspect of this exemplary embodiment canallow a CDC worker to load bulk delivered packages into the bins of manySBU's without needing to plug and unplug a network connector in and outof the scanner port of each SBU. The feature of being able to capture aunique identity and associate it with a scanning device can allow a CDCworker to be able to connect to different SBU's and associate theloading actions at each of those SBU's with their Employee Id withouthaving to re-scan their employee id card at each new SBU. These twofeatures can both be enabled as part of an embodiment in which awireless data architecture is used in a CDC, or each feature can beenabled without the other in other separate embodiments.

In still a further embodiment of the invention, cases, CDC outboundpackages, item return packages, and/or bulk delivered packages can besorted, picked, and/or redirected using automated sorting and pickingequipment and programs to move them through a RDC to the places wherethey can be loaded into RDC shipments, used to create bulk deliveredpackages, loaded into delivery shipments, or loaded into RDC returnsshipments. Automated equipment including optical reading devices mountednear or on conveyors carrying the cases and different types of packagescan read barcode or other imprinted formats on the case labels anddifferent package labels to determine if a case or package should bepicked. If an automated picking program determines that a case orpackage should be picked from a conveyor or redirected to anotherconveyor, based upon the data read from the optical reading device, itcan initiate a mechanical device to pick or redirect the case or packagefrom the conveyor. In this embodiment, automated programs and machinerycan be used, for example, in place of workers to perform the part of theRDC sort in which cases bound for the current RDC can be picked from theoutbound section of the RDC sort conveyor (18) to the local market sortconveyor (24). Another example, in which automated programs andmachinery can be used is to replace one or more workers that regulatethe flow of cases from the RDC inbound conveyor (34) to the local marketsort conveyor (24) by moving the case diverting section of the RDCinbound conveyor (38) at the right times. Automated sorting and pickingprograms of this nature can also be used to perform the local marketsort function and CDC sort function.

In still a further embodiment of the invention, automated sortingprograms and equipment can be used to organize delivery shipments andRDC returns shipments into full-trailer-loads. Optical reading equipmentto read the label plates containing Delivery Shipment Id's and/or RDCReturns Shipment Id's can provide the data inputs to an automatedsorting programs that can move the CDC feed of a CDC package conveyor(47A) and the different independent conveyor sections of the localmarket feed of a CDC package conveyor (47B) to position differentdelivery shipments near each other to create a full-trailer-load.Similarly, an automated sorting program can initiate the RDC returnsshipment conveyor (62) to move one or more RDC returns shipments intoclose proximity of one or more delivery shipments on a package conveyor(46A or 46B) to create a full-trailer-load.

In yet another embodiment of the invention, sophisticated automatedpicking and packing equipment can be used to pick items from cases andredirect them into the open packages in which they should be packed. Theautomated equipment can be integral part of the physical hardware thatmakes up a CDC packing station and can function, when directed by thePackage Creation Program (330), to insert printed packing lists intobulk delivered packages, close and seal bulk delivered packages, opennew bulk delivered packages, and label package bags. In a further aspectof the invention, additional equipment can be added to or changed on aCDC packing station (45) to aid a worker in setting up new bulkdelivered packages and in closing and sealing bulk delivered packages,by automating the process of putting a new package bag in a package bagholder or sealing a package bag in a more automated manner. A packagebag can be closed and sealed while still in its package bag holder (71or 72) and the package sealing side of a CDC packing station (FIG. 5)may not need to exist separately from the package creating side of a CDCpacking station (FIG. 4).

A further embodiment of the invention can include programs playing briefaudio messages instead of sounding tones to convey a more descriptivemessage. This embodiment can include programs that run in a RDC, CDC, orretailer fulfillment site. The workers using the different programs maywear headsets or ear-bud headphone pieces to ensure that they candifferentiate the audio messages intended for them from the ones createdby other instances of the same program or other programs, which can beintended for other workers. For example, when a worker performing thelocal market sort in a RDC scans a case on the CDC sort conveyor (42),at which the worker is stationed, to pick and remove it from the currentlocal market, back to the local market sort conveyor (24), the LocalMarket Sort Program (326) can play a brief audio message to confirm thata reverse local market sort pick has been processed successfully, suchas, “reverse pick confirmed”. Any combination of tones, brief audiomessages, text messages displayed on workstation display monitors, textmessages displayed on scanning devices, and/or indicator lights can beused to alert a worker to a message and relay various messagesincluding, but not limited to warning messages, confirmation messages,error messages, directions, suggestions, and commands.

A further embodiment of the invention can include employing a differentamount of validation in the different programs. More validation stepscan be added to programs in situations where errors can be more likely,more critical, and/or when the processing required to complete theadditional validation does not adversely impact the speed and ease ofusing that program.

In a further embodiment of the invention, Bin Inventory table records1300 can exist for every possible bin configuration. There can be anActive Status field on the Bin Inventory table 1300, which can be usedto activate and deactivate each record by changing its value from avalue such as “inactive” to a value such as “active” and vice versa. Asthe SBU Configuration Program (352) is run, in this embodiment, theActive Status field on Bin Inventory records 1300 associated with amaster bin can be updated to reflect the configuration changes made tothat master bin. For example, if a master bin that is divided into twobins, each with a Bin Size of “2”, is configured to become one largeundivided bin, it will start with two Bin Inventory records 1300 thathave an Active Status with a value such as “active”—one of those recordshaving a Configuration Code value such as “12” and the other having aConfiguration Code value such as “34”. After the configurationadjustment gets made, both of the records which had an Active Statusvalue such as “active” will have an Active Status value such as“inactive”. The Active Status of the Bin Inventory record 1300associated with that master bin that has a Configuration Code such as“1234”, can be updated from a value such as “inactive” to a value suchas “active”. The number of records on the Bin Inventory table 1300 canbe much larger than if inactive records were not listed on the table1300. Configuration adjustment changes can be made more easily, byupdating the Active Status field on a few Bin Inventory records 1300associated with a SBU master bin, instead of creating new Bin Inventoryrecords 1300 and/or deleting existing ones.

In a further embodiment of the invention, each individual case can bescanned to associate it with a retailer shipment, when loading casesinto a trailer at a retailer fulfillment site. A Pick List Report doesnot need to be broken up into pick grouping sections and a workerloading a retailer shipment onto a trailer does not need to scan PickGrouping Id's as the cases of a retailer shipment are loaded. The workerdoes need to scan each case as it is loaded onto a trailer to associateit with the retailer shipment. The Retailer Shipment Program (312) canupdate the Case record 1208 of each case as it is scanned into aretailer shipment by setting its Status to a value such as “on trailer”and writing the Retailer Shipment Id of the current retailer shipment tothe Retailer Shipment Id field of the record 1208, instead of updating agroup of Case records 1208 having a Pick Grouping Id, as that PickGrouping Id is scanned on a Pick List Report. The Retailer ShipmentProgram (312) can also update Order Detail records 1202 with thatRetailer Shipment Id and a Status value such as “retailer shipment—backorder” or “retailer shipment—new” (depending upon whether its Status was“pick list—back order” or “pick list—new”), for Order Detail records1202 having the SKU of the scanned case, up to the Quantity of thescanned case.

In still a further embodiment of the invention, a group of cases withsequential Case Id's can be associated with a retailer shipment byscanning the case label of the first and last case in the retailershipment. Cases can be picked in the sequence in which they can belisted on a Pick List Report and loaded as a retailer shipment in thesequence in which they were picked. In this embodiment, a set ofsequential Case Id's can be loaded onto a trailer as a retailer shipmentas the worker loading the cases onto the trailer can, for example, scanthe case label of the first and last case being loaded, after scanningtheir employee id card and the trailer label. The Retailer ShipmentProgram (312) can update the Case record 1208 of the two scanned casesand all of the Case records 1208 listed sequentially in between thosetwo records on the Case table 1208. The Retailer Shipment Program (312)can update the Case records 1208, and can select and update Order Detailrecords 1202, in this embodiment, consistent with the way in which theRetailer Shipment Program (312) can update Case records 1208 and canselect and update Order Detail records 1202 that can be added to aretailer shipment via a scanned Pick Grouping Id in the main embodiment.

In a further embodiment of the invention, cases of ordered items can belabeled as they are received at an origination RDC. The Pick List ReportProgram (310) can print a Pick List Report that lists the total numberof cases of each SKU that should be picked, but does not contain caselabels. The Pick List Report Program (310) can create Case records 1208in the same way as described in the main embodiment. Workers at aretailer fulfillment site can pick the total number of cases needed tofill the orders listed on the Pick List Report and can load them ontoone or more trailers as retailer shipments. All the Case records 1208created by the Pick List Report Program (310) can be sent in a data fileor copied through a remote data connection to the database of theorigination RDC, to which the retailer shipments containing the casespicked using that Pick List Report are being sent, when the Pick ListReport Program (310) is run. Order Detail records 1202 can be selectedand sent/copied, so that the total Quantity of all the selected OrderDetail records 1202, that have a particular SKU, equals the totalQuantity of all the Case records 1208 created by the Pick List ReportProgram (310), which have that same SKU. The Order Header records 1200associated with the selected Order Detail records 1202 can also beselected and sent/copied to the RDC database. In this embodiment,Retailer Shipment records 1212 are not created and Case 1208 and OrderDetail 1202 records are not updated with a Retailer Shipment Id or adifferent Status when the picked cases are shipped from the retailerfulfillment site as a retailer shipment. Workers at the RDC, receivingretailer shipments sent from retailer fulfillment sites, can run aprogram which can print case labels using the Case records 1208sent/copied from the retailer's database and can update the Status ofthe copied Case 1208 and Order Detail 1202 records to a value such as“origination RDC”. The RDC workers can then label each case as it isreceived into the origination RDC. The labeled cases can then beprocessed at the RDC consistent with the description of the mainembodiment. This can shift the effort involved in labeling picked casesfrom workers at a retailer fulfillment site to the workers at anorigination RDC, but it may be prone to labeling errors, and it does notprovide accurate visibility as to the location of a picked case from thetime it is printed on a Pick List Report until the time that it islabeled at the origination RDC.

A further embodiment of the invention can include, labeling cases whenthey are organized into a retailer shipment at the retailer fulfillmentsite, instead of when they are picked. The Pick List Report Program(310) can print a Pick List Report containing case labels, but theworkers using the report to pick the cases can refrain from labelingcases as they are picked. The cases can be labeled at the shipping dock,after they have been picked, as they are being organized into a retailershipment. In this embodiment, the Retailer Shipment Program (312) canupdate Case 1208 and Order Detail 1202 records to associate them with aretailer shipment in a way consistent with the main embodiment, theembodiment in which each case is scanned to associate it with a retailershipment, or the embodiment in which cases can be associated with aretailer shipment sequentially in between two scanned case records.

In a yet a further embodiment of the invention, the trailers upon whichRDC shipments have been loaded can be moved to a RDC inbound receivingdock (31) or from a RDC shipping dock (52) using loading equipment whichcan be found in an intermodal rail yard. The loading equipment can belocated in between the RDC and a rail line adjacent to the RDC. In thisembodiment, trailers can be moved from a train to the RDC inboundreceiving dock (31) of a RDC, from the RDC inbound receiving dock (31)to the RDC shipping dock (52) of the RDC, and from the RDC shipping dock(52) to a train using loading equipment instead of a drayage vehicle(tractor).

In still a further embodiment of the invention, large conveyors, locatedoutside of a RDC, can be used to move trailers to RDC inbound receivingdocks (31), RDC shipping docks (52), and conveyor platforms locatedalong side of a rail line. The conveyor platforms located next to therail line can serve as loading and unloading points for loadingequipment to move the trailers off of and onto a train. The othersections of the large conveyors can be used to move the trailers fromthe conveyor platforms next to the rail line to conveyor platforms nextto the RDC inbound receiving docks (31) of the RDC, from the conveyorplatforms next to the RDC inbound receiving docks (31) to conveyorplatforms next to the RDC shipping docks (52) of the RDC, and from theconveyor platforms next to the RDC shipping docks (52) to the conveyorplatforms next to the rail line.

In a further aspect of the invention, the Package Creation Program (330)can consider ordered items, which can be on RDC shipments heading forthe destination RDC in which the program (330) can run, when determiningwhen to close a bulk delivered package that can be in the process ofbeing created. In addition to creating a RDC Shipment Receiving recordon the destination RDC database when a RDC shipment is sent from itsorigination RDC, the RDC Shipment Loading Program (320) can also copythe Case 1208, Order Header 1200, and Order Detail 1202 records, thathave the RDC Shipment Id of the RDC shipment being sent, from theorigination RDC database to the destination RDC database. The OrderDetail 1202 and Case 1208 records can be copied with a Status value suchas “RDC shipment” and Order Header record 1200 can be copied with aStatus value such as “open”, but in this embodiment, the SKU by CustomerOrder List data view 1230 can be created by selecting fields from OrderDetail records 1202 and their associated Order Header records 1200 whichhave an Order Detail.Status value such as “destination RDC” or “RDCshipment” and an Order Header.RDC Id equal to the value of the currentRDC. If items have been picked and packed into a bulk delivered packageto meet the item quantities on all of the Order Detail records 1202having a particular CDC Id-Customer Id-Temperature Code combination anda Status value such as “destination RDC”, but there is still at leastone Order Detail record 1202 having that CDC Id-Customer Id-TemperatureCode combination, a Status value such as “RDC shipment”, and anassociated Order Header record 1200 with an RDC Id equal to the value ofthe current RDC, the Package Creation Program (330) can refrain fromclosing that bulk delivered package.

A further embodiment can include a more automated CDC packing station(45) featuring moving package bag holders that can move the package bagholder in which a worker is being directed to pack a picked item (thehighlighted package bag holder) in front of the worker that is creatingbulk delivered packages at that CDC packing station (45). The automatedCDC packing station (45) can have, for example, large and small packagebag holders arranged in a circular structure, which rotates to move thepackage bag holders.

In a further embodiment, bulk delivered packages can be created innon-bubble wrap bags, boxes, or other suitable containers, in additionto bubble wrap bags. The bags, boxes, or other containers should bepre-sized to fit into the standard SBU bin sizes, however.

In yet another embodiment of the invention, the RDC Returns ShipmentCreation Program (341) can allow workers to still work as a team tocreate RDC returns shipments for the retailers of a local market, eventhough each worker can be using a different instance of the RDC ReturnsShipment Creation Program (341). There can only be one open RDC returnsshipment for a retailer, and each worker on the team can add item returnpackages to any of the open RDC returns shipments. The scanning devicesdo not need to have unique identifiers and there can be a differentdisplay screen (which can include, but is not limited to a programdisplay monitor, small LCD screen mounted to a fixed base, or a smallLCD screen built into the scanning device) for each instance of the RDCReturns Shipment Creation Program (341). Each display screen can displaythe program messages specific to the instance of the RDC ReturnsShipment Creation Program (341) associated with that display screen. Ina further aspect of the invention, the RDC Returns Shipment CreationProgram (341) can feature a Returns Shipment Creation Screen that canlook and function similar to the Package Creation Screen—instead ofhaving numbered shapes representing package bag holders, it can havenumbered shapes which represent conveyors, upon which cargo cages andsingle-item return packages can be organized into RDC returns shipmentsby retailer. A set of conveyors upon which RDC returns shipments can becreated can be located in between a CDC sort conveyor (42) and a RDCreturns shipment conveyor (62). The set of conveyors can be positionedso that a RDC returns shipment can flow from each one onto the RDCreturns shipment conveyor (62). Each instance of the RDC ReturnsShipment Creation Program (341) can guide a worker to pick scanned itemreturn packages and can add them to an existing RDC returns shipment ona specific numbered conveyor or create a new RDC returns shipment foritem return packages on one of the open numbered conveyors. The RDCReturns Shipment Creation Program (341) can associate a conveyor withthe RDC returns shipment located on that conveyor, and workers can scanthe RDC returns shipment label of a RDC returns shipment when adding apicked item return package to a RDC returns shipment. Although eachworker can be using a separate instance of the RDC Returns ShipmentCreation Program (341), workers can work in teams to create the RDCreturns shipments, there can only be one open RDC returns shipment for aretailer, and each worker on the team can add item return packages toany of the open RDC returns shipments.

In a further aspect of the invention, the RDC Returns Shipment CreationProgram (341) can feature a Returns Shipment Creation Screen, eachworker can use a separate instance of the RDC Returns Shipment CreationProgram (341), and each worker can create a limited number of separateRDC returns shipments instead of working as a team with other workers tocreate RDC returns shipments. As a worker scans an item return package,the RDC Returns Shipment Creation Program (341) can check to see if thatworker has an open RDC returns shipment for the retailer associated withthe scanned item return package. If the worker has an open RDC returnsshipment for the retailer associated with the scanned item returnpackage, the RDC Returns Shipment Creation Program (341) can direct theworker to pick the item return package and place it into the RDC returnsshipment on the conveyor that it highlights on the Returns ShipmentCreation Screen. If the worker does not have an open RDC returnsshipment for the retailer associated with the scanned item returnpackage, the RDC Returns Shipment Creation Program (341) can check tosee if another worker has a open RDC returns shipment for the retailerassociated with the scanned item return package. If another worker hasan open RDC returns shipment for that retailer, the RDC Returns ShipmentCreation Program (341) can direct the worker not to pick the item returnpackage. If there is not an open RDC returns shipment for that retailer,the RDC Returns Shipment Creation Program (341) can direct the worker topick the item return package and create a new RDC returns shipment. In afurther aspect of the invention, RDC workers can use the RDC ReturnsShipment Creation Program (341) to create a limited number of separateRDC returns shipments, but the RDC Returns Shipment Creation Program(341) can allow each worker to create a new RDC returns shipment for aretailer, even if another worker has an open RDC returns shipment forthat retailer. The processing step of checking for which retailers otherinstances of the RDC Returns Shipment Creation Program (341) have anopen RDC returns shipment can be eliminated. RDC returns shipments boundfor the same retailer can optionally be grouped together, before theyare moved to a local market shipping dock (50), when full-trailer-loadsof RDC returns shipments and delivery shipments are created. In afurther embodiment of the invention, delivery shipments can be loadedonto an outbound trailer and shipped from a RDC without reserving binspace for the bulk delivered packages and CDC outbound packages of thatdelivery shipment. The Delivery Shipment Program (342) can still print alisting on a Delivery Shipments Report for each delivery shipment loadedonto a trailer, and when a delivery shipment is received into a CDC, thebarcode on the Delivery Shipments Report associated with that deliveryshipment can be scanned and used by the Loading Guide Report Program(354) to create a Loading Guide Report. CDC workers can use the LoadingGuide Report to assist them as they load the bulk delivered packages andCDC outbound packages of a delivery shipment into SBU bins. If there arenot enough SBU bins available in the CDC to receive all of the bulkdelivered packages and CDC outbound packages of a delivery shipment, thepackages that are not able to be loaded into SBU bins can be stored in aholding cage (134) associated with the shipper delivering the deliveryshipment.

In still a further embodiment of the invention, the ConfigurationAdjustments Report Program (344) is not initiated by the DeliveryShipment Program (342) as part of loading a delivery shipment onto atrailer, but it can be run periodically to adjust the number of bins ofeach bin size to meet the appropriate levels determined by bin usagetrend reporting. This can be employed to set the number of bins of eachbin size to an optimal level, which can reduce the effort that may berequired to make bin configuration adjustments to try to meet the binspace requirements of every delivery shipment sent to a CDC. A bin usagetrend report can be created from data snapshots of a CDC's available bincapacity, the number of bulk delivered packages and CDC outboundpackages shipped to a CDC in a day, and the number of bulk deliveredpackages and CDC outbound packages removed from delivery shipments of aCDC, to show the optimal numbers of bins of each bin size for a CDC. Thebin usage trend reporting can be run separately for each CDC or acrossgroups of CDC's. The Configuration Adjustments Report Program (344) canuse the output from the bin usage trend report, a data view created fromthe Bin Inventory table of a CDC as a summary of the number of bins ofeach Bin Size, and the Unreserved Bins data view 1305 to determine thenumber of bin configuration adjustments to make in a CDC. In one aspectof the invention, a Configuration Adjustments Report can print in a CDCand can be used by a shipper or the entity running a CDC to make binconfiguration adjustments in the same manner as described in the mainembodiment. If there are not enough SBU bins available in a CDC toreceive all of the bulk delivered packages and CDC outbound packages ofa delivery shipment, the number of packages of each package size, abovethe amount which can be reserved for the current delivery shipment, canbe removed from the current delivery shipment by the ShipmentAdjustments Report Program (345) as described in the main embodiment.

A further embodiment of the invention can include using holding cages(134) or excess secured storage space in the backroom area (154) of aCDC to allow one or more shippers to deliver more bulk deliveredpackages and CDC outbound packages to a CDC before needing to makedelivery shipment adjustments to the delivery shipments it sends to thatCDC. The Shipment Adjustments Report Program (345) can be configured toallow a predetermined number or a percentage of bulk delivered packagesabove that CDC's remaining capacity of available SBU bins to be shipped.

A further embodiment of the invention can include cargo cages which canhave retractable wheels. These cargo cages can be received into a CDConto a dock conveyor and then pushed or pulled through the CDC by one ormore CDC workers unloading packages from that cargo cage. The cargocages can be linked together to form larger groups of bulk deliveredpackages that can be easily movable throughout a CDC, without the use ofmobile putaway conveyor units (143).

In a further embodiment of the invention, package recipients can benotified of the receipt of a bulk delivered package or a CDC outboundpackage only once. Although the functionality to call/send remindernotifications to a recipient is not available in this embodiment, theNew Package Notification Program (358) and the Notification Program(360) can still work together with the Customer table 1256 to notify apackage recipient according to their recorded preferences and to preventthem from receiving a separate notification message for each bulkdelivered package received, if more than one bulk delivered package isreceived before the recipient retrieves their bulk delivered packages.

In still a further embodiment of the invention, notification messagescan be customized by each shipper to include standard information, suchas a description of their package retrieval policies, or situationspecific information based upon factors including, but not limited tothe time elapsed since the delivery notification of a bulk deliveredpackage, the number of packages currently in a CDC for a packagerecipient, seasonal-based factors, and CDC location-based factors. Aseparate table can be used to store different predefined messages thatcan be selected for use in an electronic notification message dependingupon the values of other fields on that table. This can provide shipperswith the capability to change the content of notification messages sentto package recipients and can allow them to have several situationalnotification messages that can be selected and played based upon otherfactors.

A further embodiment can include sending a notification message to apackage sender when a CDC outbound package that the package sender senthas been delivered to a CDC. A package sender can indicate the desire tobe notified when the CDC outbound package the sender is sending isdelivered—delivered to its destination CDC and loaded into a SBU bin. Anindicator field on a CDC Outbound Package record 1270 can be used totrack whether a package sender selected this feature and can be used bythe New Package Notification Program (358) to create a NotificationQueue record 1311 containing a field to indicate that the record is fornotifying a package sender and not a package recipient. Upon checkingthe value of that indicator field when processing Notification Queuerecords 1311, the Notification Program (360) can initiate the Auto-callProgram (362) and/or the Auto-e-mail Program (364) to contact thepackage sender. After one or more messages are sent to the packagesender successfully, in accordance with the package sender'snotification preferences, the Notification Program (360) can delete thepackage sender's record from the Notification Queue 1311. A differentmessage can be played for notifying a package sender than a packagerecipient. If a customer is both a package sender and a packagerecipient at the same time, the customer can have more than one recordon the Notification Queue table 1311, and the customer can be contactedseparately with each type of message. A package sender notificationmessage can include the package recipient's name, and a package sendercan receive a distinct message for each CDC outbound package the packagesender sends, regardless of when those packages are delivered. TheNotification Program (360) can be configured to treat Notification Queuerecords 1311 for package senders with the same priority as NotificationQueue records 1311 for package recipients, or they can be treated with adifferent priority.

In a further embodiment of the invention, a CDC can have separatereturns processing entry points (148) for each shipper accepting itemreturn packages and/or CDC outbound packages at that CDC. This canresult in customers/recipients naturally segregating item returnpackages and/or CDC outbound packages by shipper when they send an itemreturn or a CDC outbound package, allowing for the CDC workers of eachshipper to more easily identify item return packages and CDC outboundpackages marked for their shipping organization when creating CDCreverse shipments.

In a further embodiment of the invention, an ePD customer access cardcan be used at a SBU along with an entered PIN to retrieve a bulkdelivered package instead of entering a Quick Code and PIN on the SBUkeypad (244).

In still a further embodiment of the invention, a Customer Id and PINcan be entered on a SBU keypad (244) to retrieve a bulk deliveredpackage instead of entering a Quick Code and PIN on the SBU keypad(244). In a further embodiment, shippers can bill the customers placingorders, instead of the retailers accepting those orders. The amountbilled can be based upon factors including, but not limited to a flatshipping fee per order, a fee based upon the number of items in anorder, a fee based upon the weight of an order, a fee based upon thevalue of an order, a fee based upon package size, a fee based upon thenumber of packages in an order, location-based storage rates, andseasonal-based storage rates.

In still a further embodiment, the entity operating a CDC can chargeretailers, shippers, or customers a storage fee for each package ororder delivered based upon factors including, but not limited to thenumber of SBU bins used to hold the packages of an order, the size ofeach SBU bin used to hold each package, the amount of time that apackage is in a SBU bin after the package recipient was notified ofdelivery, a flat storage charge per order, a storage charge based uponthe value of an order, a flat storage charge per package depending uponpackage size, location-based storage rates, and seasonal-based storagerates.

Yet another embodiment can include retailers creatingtemperature-controlled bulk delivered packages at their fulfillmentsites for regional distribution to CDC's and LDDH's in the local marketsserved by a RDC. The retailers can create bulk delivered packages thatrequire refrigeration or sub-freezing temperatures using a RetailerPackage Creation Program (315) or a modified version of their own orderfulfillment software. Each bulk delivered package created at a retailerfulfillment site can have an associated Package record (which can be ofthe same data structure as described in the main embodiment), a packinglist, and a package label (which can be of the same format as describedin the main embodiment). The temperature-controlled bulk deliveredpackages can be shipped to a shipper's RDC in cargo cages or any othersuitable container on a temperature controlled tractor-trailer or othercargo carrying vehicle. The retailer shipment containingtemperature-controlled bulk delivered packages can arrive at a RDC andcan be unloaded from a trailer conveyor (204) to atemperature-controlled receiving dock in the same way that retailershipments of cases can be unloaded from trailers and moved into a RDC inthe main embodiment. The Package 1234, Order Header 1200, and OrderDetail 1202 records associated with the temperature-controlled bulkdelivered packages can be copied from the retailer's database to thedatabase on the RDC server using a method similar to the one used tocopy Case 1208, Order Header 1200, and Order Detail 1202 recordsassociated with a retailer shipment of cases. After the cargo cages orother containers filled with the temperature-controlled bulk deliveredpackages of the temperature-controlled retailer shipment are moved ontoa temperature-controlled receiving dock in the RDC, RDC workers canempty the cargo cages and/or other suitable containers filled with thetemperature-controlled bulk delivered packages onto thetemperature-controlled local market sort conveyor. RDC workersperforming the temperature-controlled local market sort can picktemperature-controlled bulk delivered packages from thetemperature-controlled local market sort conveyor and place them on thetemperature-controlled CDC sort conveyors at which they can be stationedby reading the Local Market Id embedded in the CDC Id printed on thepackage label or scanning the barcode on the package label using aprogram similar to the Local Market Sort Program (326) that is able toprocess scanned Package Id barcodes and direct a worker to pick orignore temperature-controlled bulk delivered packages for the localmarket of the temperature-controlled CDC conveyor at which that workeris stationed. RDC workers creating temperature-controlled deliveryshipments for a particular CDC or LDDH can scan and picktemperature-controlled bulk delivered packages from thetemperature-controlled CDC sort conveyor at which they are stationed andcan place them into a temperature-controlled delivery shipment. Theentire area where temperature-controlled bulk delivered packages can bereceived, sorted, and added to temperature-controlled delivery shipmentscan be located in a temperature-controlled area within a RDC, or atleast the location in which parts of that process occur can be locatedin a temperature-controlled area of the RDC. Temperature-controlleddelivery shipments can be loaded onto temperature-controlledtractor-trailers (or similar vehicles), organized by local market, andshipped from the RDC to one or more CDC's or LDDH's in a local market.CDC workers meeting a temperature-controlled vehicle carryingtemperature-controlled delivery shipments at a CDC 1190-1 can unload thetemperature-controlled delivery shipment and immediately move throughthe CDC 1190-1 to load the temperature-controlled bulk deliveredpackages into the bins of SBU's located in a temperature-controlled areaof the CDC.

In a further aspect of the invention, retailer-createdtemperature-controlled bulk delivered packages, shipped to a RDC forregional distribution to CDC's and LDDH's in the local markets served bythat RDC, can be received into and moved through a RDC using the sameconveyors and programs that can be used to move cases, bulk deliveredpackages, and CDC outbound packages through the RDC. Thetemperature-controlled retailer shipments can be received onto a RDCinbound receiving dock conveyor (32) and moved into the local marketsort process. The retailer-created temperature-controlled bulk deliveredpackages can be labeled with color-coded labels or a label with amarking to indicate that the package is a retailer-createdtemperature-controlled bulk delivered package and not a standardtemperature bulk delivered package, CDC outbound package or an itemreturn package, to allow RDC workers to give first priority totemperature-controlled bulk delivered packages as they can be movedthrough the RDC. Temperature-controlled bulk delivered packages can beidentified and picked from the local market sort conveyor (24) withoutbeing scanned (similar to CDC outbound packages and item returnpackages). The Delivery Shipment Creation Program (340) can determinethat a scanned temperature-controlled bulk delivered package isdifferent from a bulk delivered package by checking the Temperature Codeon its Package record 1234 and can direct a worker to segregate the twotypes of bulk delivered packages into different delivery shipments. RDCworkers can organize full-trailer-loads of temperature-controlleddelivery shipments and load them onto temperature-controlled trailers.

In a further aspect of the invention, the retailer-createdtemperature-controlled bulk delivered packages can be shipped to a RDCwhich can be specialized to process retailer-createdtemperature-controlled packages for regional distribution to CDC's andLDDH's in the local markets served by that specialized RDC. Thisembodiment is essentially the same as the previous one, except that theentire RDC facility can be specialized to only process retailer-createdtemperature-controlled packages.

A further aspect of the invention can include retailers sending cases oftemperature-controlled items to a RDC, where they can be processed usingthe same infrastructure that is used to process standard-temperaturecases to create temperature-controlled bulk delivered packages forregional distribution to CDC's and LDDH's in the local markets served bythat RDC. The cases of temperature-controlled items can be received ontoa RDC inbound receiving dock conveyor (32) and moved into the localmarket sort. Cases of temperature-controlled items can, for example, belabeled with a different color label or marked in some way to indicatethat they contain temperature-controlled items. RDC workers performingthe local market sort and the CDC sort can give a higher priority tocases of temperature-controlled items to move them through the RDCfaster. Items can be picked from cases containing temperature-controlleditems to create temperature-controlled bulk delivered packages.Temperature-controlled bulk delivered packages can be added totemperature-controlled delivery shipments and can be shipped to CDC's orLDDH's on temperature-controlled vehicles.

In yet still a further aspect of the invention, cases oftemperature-controlled items can be shipped to a RDC specialized toprocess temperature-controlled items, for regional distribution to CDC'sand LDDH's in the local markets served by that specialized RDC. Here,the entire specialized RDC facility only processestemperature-controlled items.

In a further aspect of the invention, cases of temperature-controlleditems can be shipped to a RDC to be processed for national ormulti-national distribution. Here, cases of standard-temperature itemsand cases of temperature-controlled items can be mixed together as theyenter the different sorting steps throughout the RDC (RDC sort, localmarket sort, CDC sort, and package conveyor sort). The RDC ShipmentProgram (318) validating whether a scanned case should be added to a RDCshipment, can check that the Temperature Code of a case matches theTemperature Code of a RDC shipment as well as checking that its RDC Idmatches the RDC Id of the RDC shipment. Temperature-controlled RDCshipments can be sent from one RDC to another on temperature-controlledtrailers or vehicles in accordance with the same process asstandard-temperature RDC shipments. Although cases ofstandard-temperature items and cases of temperature-controlled items canbe mixed together, RDC workers performing the local market sort and CDCsort can, for example, recognize cases of temperature-controlled itemsby a different color or marking on their case label and can move themthrough the RDC with a higher priority. The Package Creation Program(330) can be designed to create separate bulk delivered packages foritems of different Temperature Codes and temperature-controlled bulkdelivered packages can be added to separate temperature-controlleddelivery shipments which can be organized together and sent out to CDC'sor LDDH's in a local market. A further aspect of the invention caninclude the use of specialized RDC facilities that only handletemperature-controlled items to be processed for national ormulti-national distribution.

It should be readily understood that the transporting of trailers filledwith cases of items from a retailer fulfillment site to a RDC can beachieved by using, for example, a tractor-trailer, a locomotive, anairplane, a ship (whether local or an ocean vessel) depending upon wherethe two sites can be located and the cost and timing of eachtransportation method. The aforementioned transportation methods, or anycombination thereof, can also be used to transport trailers filled withRDC shipments between two different RDC's, trailers filled with deliveryshipments from a RDC to CDC's or LDDH's, trailers filled with RDCreturns shipments from a RDC to retailer returns facilities, or trailersfilled with CDC reverse shipments from CDC's to a RDC. Use of airplanesto transport the different types of shipments can be especially usefulin providing an expedited delivery service to deliver packages to CDC'sor customer specified addresses faster. Use of ocean vessels may beespecially economical to transport the different types of shipmentsbetween RDC's located in different countries. In one aspect of theinvention, retailer shipments, RDC shipments, delivery shipments, RDCreturns shipments, and/or CDC reverse shipments can be furthertransported on a vehicle, which is not a trailer, but has carryingcapacity sufficient to hold cargo. This can include, but is not limitedto, utility vans, cargo vans, flat beds, and pickups. In a furtheraspect of the invention, the trailers or other vehicles used totransport retailer shipments, RDC shipments, delivery shipments, RDCreturns shipments, and/or CDC reverse shipments, may not be equippedwith trailer conveyors and can require manual or mechanized labor forhandling cargo. For example, the cases, cargo cages, single-item bulkdelivered packages can be moved into and out of the trailers or othervehicles by hand or by using conventional cargo moving equipment, suchas a fork lift.

In still a further embodiment of the invention, discounts or penaltiescan be offered to recipients and/or customers to provide an incentive toretrieve bulk delivered packages from a CDC as soon as possible. Ashipper's standard package retrieval policy can include a reasonablegrace period of time that a package recipient has to retrieve their bulkdelivered packages from a CDC before incurring a penalty. The time thata bulk delivered package remains in a SBU bin at a CDC after a packagerecipient has been notified that a package has been delivered can bemeasured against a grace period by a shipper using the information onthe Bin Inventory table 1300. Various penalties can be calculated if oneor more bulk delivered packages remain in a CDC after the packagerecipient has been notified of delivery, including, but not limited tothe following: a flat charge to cover all bulk delivered packages in theCDC each time at least one bulk delivered package is left in a CDC overthe grace period; a charge per package; a charge per package, per day; acharge per package, depending upon package size; a charge per package,per day, depending upon package size; a charge per order; and a chargeper order, per day. Incentives can also be offered to package recipientsfor retrieving bulk delivered packages prior to the end of the graceperiod, such as a discount on future shipping costs. Incentives can alsobe calculated as a flat discount or can be based upon the same perpackage, per day, per order factors that a shipper may use to calculatea penalty. The net balance of penalty charges and incentive discountscan be tracked for a recipient or customer, by each shipper, in anaccount balance field. A shipper can apply a recipient's/customer's netaccount balance into the shipping cost of that recipient's/customer'snext ePD delivery or traditional delivery order when therecipient/customer selects the shipper from the retailer's web site. Ashipper's standard package retrieval policy can be communicated in anotification message to a package recipient, as well as specificinformation related to the package recipient's package retrievalsituation. For example, a reminder notification message can inform apackage recipient that the recipient will be charged a fee on at leastone of their packages if the recipient does not retrieve their packagesby the end of the current day. A shipper may vary the penalties andincentives they offer at different seasonal times or by CDC location.

In a further embodiment of the invention, portable temporary SBU'slocated, for example, on trailers in a parking lot of the CDC or anothersuitable location can be used to increase the bin capacity of a CDC tomeet seasonal peak demands. The portable temporary SBU's can betransported to a CDC location on a tractor-trailer. The trailerscontaining the additional SBU's can be detached from their tractors andparked near the CDC. The sides of the trailers can, for example, roll upor be removed to allow workers and recipients to access the SBU's, whichcan sit back to back facing out through each open side of the trailer.The SBU's can be connected to the CDC server and to power sources insidethe CDC by a protected cable connection running from the CDC to thetrailer. Temporary platforms with ramps and/or stairs can be positionednext to the trailers containing additional SBU's to allow customers toaccess the SBU's. A large tent or awning can be temporarily constructedover groups of the trailers containing the additional SBU's to provideshelter to protect the SBU's and recipients and workers accessing theSBU's from adverse weather conditions. One or more temporary scaled downversions of entrance stations without electronic locking doors can beset up near the groups of trailers containing the additional SBU's toallow recipients to determine in which SBU's their bulk deliveredpackages can be located and to receive the Quick Code needed to accesstheir bulk delivered packages. Records can be added to the Bin Inventory1300 and SBU Settings 1314 tables for the additional SBU's temporarilyadded to the CDC (the added records can later be deleted if theadditional SBU's are later removed from the CDC). Alternatively,additional SBU's can be moved on tractor-trailers and then unloaded fromthe trailers and moved onto platforms or onto the ground in the CDCparking lot or a nearby area. In a further aspect of the invention,additional temporary CDC locations can be added as needed in localmarkets to meet seasonal demands. A suitable commercial location can berented and SBU's can be moved into that commercial location along withthe hardware for one or more entrance stations or scaled down versionsof entrance stations without electronic locking doors. A CDC processingserver can also be moved into the location and can be configured for theSBU's that were moved into the location. A temporary CDC location canoperate in the same manner as a permanent CDC location.

While exemplary systems and methods embodying the present invention areshown by way of example, it should be understood that the invention isnot limited to these embodiments. Modifications can be made by thoseskilled in the art, particularly in light of the foregoing teachings.For example, each of the elements of the aforementioned embodiments maybe utilized alone or in combination with elements of the otherembodiments.

1. A method for efficiently delivering packages in bulk for recipients comprising: transporting containers of items organized by item identifier to a distribution center; creating a package at said distribution center containing at least one item ordered for a recipient, by reorganizing said transported items by an identifier of a destination centralized pickup location and at least one of an identifier of said recipient and an identifier which is linked to said recipient; associating an identifier of said package with said identifier of a destination centralized pickup location; grouping a plurality of said packages for a plurality of recipients for delivery to said destination centralized pickup location based on said association of said package identifier and said destination centralized pickup location identifier; delivering said grouped packages in bulk to said destination centralized pickup location; randomly selecting a storage locker bin from a system of storage locker bins at said destination centralized pickup location; loading each delivered package into a respective randomly selected storage locker bin; and associating said package identifier of said loaded delivered package with an identifier of said randomly selected storage locker bin.
 2. The method according to claim 1, further comprising sorting at an origination distribution center items received from at least one retailer delivered to said origination distribution center, said items destined for a plurality of said recipients, said items organized by item identifier, wherein said step of creating a package occurs at a destination distribution center after said sorted items have been transported to said destination distribution center from said origination distribution center.
 3. The method according to claim 2, wherein the step of sorting said received items at said origination distribution center further comprises: identifying said received items to a destination centralized pickup location; identifying said received items to said destination distribution center; and sorting and grouping said identified received items by said identified destination distribution center, said identified received items organized by item identifier.
 4. The method according to claim 2, further comprising consolidating more than one of said items destined for a specific recipient, said more than one item originating from at least one retailer.
 5. The method according to claim 4, further comprising receiving said items associated with at least one order from least one fulfillment location.
 6. The method according to claim 1, wherein the step of randomly loading said bulk delivered package into a system of storage locker bins further comprises: capturing electronically an identifier for said bulk delivered package; and associating said electronically captured identifier of said bulk delivered package with an electronically captured identifier of one of said storage locker bins within said system of storage locker bins.
 7. The method according to claim 6, further comprising, retrieving said bulk delivered package created for said specific recipient from a storage locker bin, said retrieving step including authenticating an identity of said recipient prior to at least one of revealing an identity of said storage locker bin and providing access to said storage locker bin.
 8. The method according to claim 1, further comprising: creating a returns package comprising at least one item from at least one of a bulk delivered package retrieved by a recipient and a package delivered to a customer specified address, said returns package destined for a retailer associated with said as least one item; and delivering in bulk sorted and grouped returns packages to a returns facility of said associated retailer.
 9. The method according to claim 8, further comprising submitting said returns package pickup at a destination centralized pickup location.
 10. The method according to claim 1, wherein the step of randomly loading said bulk delivered package into said system of storage locker bins comprises automatically triggering the dispatch of an electronic notification to said recipient of said bulk delivered package, said electronic notification having at least an identifier of said destination centralized pickup location.
 11. The method according to claim 10, wherein said step of automatically triggering the dispatch of said electronic notification further comprises recording information necessary for billing at least one of a customer who ordered an item of said bulk delivered package, said recipient and a retailer, said information including at least one of an order identifier, an ordering customer identifier, a recipient identifier, a customer identifier, a package identifier, a delivery date, a delivery time, a delivery notification date, a delivery notification time, a retrieval date and a retrieval time.
 12. The method according to claim 10, wherein said electronic notification to said recipient comprises, at least one of a facsimile, an email, a telephone call, and a page.
 13. The method according to claim 1, further comprising retrieval of said bulk delivered package by said recipient through self-service.
 14. The method according to claim 1, wherein the step of loading said bulk delivered packages randomly into said system of storage locker bins further comprises loading a bulk delivered package into any unoccupied storage locker bin within said system of storage locker bins, said unoccupied storage locker bin, having dimensions large enough to accept said bulk delivered package, said system of storage locker bins being configurable.
 15. The method according to claim 1, further comprising controlling a temperature within said bins of said system of storage locker bins by locating said bins in a temperature controlled environment.
 16. The method according to claim 1, wherein said step of delivering said packages in bulk to said destination centralized pickup location further comprises accommodating delivery of said packages in bulk to said destination centralized pickup location from a plurality of different shippers.
 17. The method according to claim 1, wherein said step of loading said bulk delivered packages randomly into said system of storage locker bins further comprises accommodating loading of said bulk delivered package into said system of storage locker bins from a plurality of different shippers.
 18. The method according to claim 1, further comprising: creating a bulk delivered customer distribution center (CDC) outbound package consisting of at least one item destined for a recipient at one of a specified destination centralized pickup location and a specified address, submitting said bulk delivered CDC outbound package for pickup at a destination centralized pickup location; and delivering a plurality of said CDC outbound packages in bulk to one of said specified destination centralized pickup location and a local distribution hub.
 19. The method according to claim 1, wherein the step of grouping a plurality of packages for a plurality of recipients for delivery to said destination centralized pickup location is accomplished within the step of creating a package at said distribution center as comprised: sorting items organized by item identifier to a packing station associated with said destination centralized pickup location; and picking items identified for a specific recipient from said items organized by item identifier at said packing station associated with said destination centralized pickup location to create a package far said specific recipient.
 20. The method according to claim 1, further comprising sorting at an origination distribution center items received from at least one retailer delivered to said origination distribution center, said items destined for a plurality of said recipients, said items organized by item identifier, wherein said step of creating a package occurs at said origination distribution center, said origination distribution center also serving as a destination distribution center.
 21. The method according to claim 20, further comprising consolidating more than one of said items destined for a specific recipient, said more than one item originating from at least one retailer.
 22. The method according to claim 21, further comprising receiving said items associated with at least one order from at least one fulfillment location.
 23. A method for efficient bulk package delivery for recipients comprising: delivering said packages in bulk for a plurality of recipients in a single delivery stop to a destination centralized pickup location, and delivering at least one item destined for a recipient; loading said bulk delivered packages randomly into an automated system of storage locker bins; creating a returns package comprising at least one item from at least one of a hulk delivered package retrieved by a recipient and a package delivered to a customer specified address, said returns package destined for a retailer associated with said at least one item; identifying a returns facility identifier and a returns local market identifier for said returns package based upon an identifier of said retailer; identifying a distribution center identifier associated with said returns local market identifier; submitting said returns package for pickup at a destination centralized pickup location; transporting said submitted returns package from said destination centralized pickup location of said returns package submission to a destination distribution center associated with said destination centralized pickup location of said returns package submission; sorting and grouping at said associated destination distribution center a plurality of transported returns packages by said identified distribution center identifier associated with said returns local market identifier for bulk delivery to an origination distribution center associated with said identified distribution center identifier; transporting said sorted and grouped returns packages from said associated destination distribution center to said associated origination distribution center; sorting at said associated origination distribution center said transported returns packages by said identified returns local market identifier of each said returns package; sorting and grouping at said associated origination distribution center said sorted returns package by said identified returns facility identifier of said sorted returns package for bulk delivery to a returns facility associated with said associated returns facility identifier; and delivering in bulk said sorted and grouped returns packages to said associated returns facility.
 24. A system for efficient bulk package delivery for recipients, the system comprising: package creation means located at a distribution center for creating a package containing at least one item ordered for a recipient, the package creation means creating a package by reorganizing items transported to the distribution center originally organized by item identifier, the package being organized by an identifier of a destination centralized pickup location and at least one of an identifier of a recipient and an identifier which is linked to said recipient; associating means for associating an identifier of a created package with the identifier of a destination centralized pickup location; grouping means for grouping a plurality of packages intended for a plurality of recipients for delivery to said destination centralized pickup location based on said association of said package identifier and said destination centralized pickup location identifier; delivery means for delivering said grouped packages in bulk in a single delivery stop to said destination centralized pickup location; a system of storage locker bins at said destination centralized pickup location, from which a storage locker but is randomly selectable; means for loading each delivered package into a respective randomly selected storage locker bit; and associating means for associating the package identifier of the loaded delivered package with an identifier of the randomly selected storage locker bin.
 25. The system according to claim 24, further comprising means for sorting at an origination distribution center, items received from at least one retailer delivered to said origination distribution center, said items destined for a plurality of said recipients, and said items organized by item identifier, wherein said package creation occurs at a destination distribution center after said sorted items have been transported to said destination distribution center from said origination distribution center.
 26. The system according to claim 25, wherein said means for sorting said received items at said origination distribution center, location further comprises: identification means for identifying said received items to a destination centralized pickup location; identification means for identifying said received items to a destination distribution center; and means for sorting and grouping said identified received items by said identified destination distribution center, said identified received items organized by item identifier.
 27. The system according to claim 25, further comprising consolidation means for consolidating more than one of said items destined for a specific recipient, said more than one of said items originating from at least one retailer.
 28. The system according to claim 27, further comprising means for receiving said items associated with at least one order from at least one fulfillment location.
 29. The system according to claim 24, further comprising: means for creating a returns package consisting of at least one item from at least one of a bulk delivered package retrieved by a recipient and a package delivered to a customer specified address, said returns package destined for a retailer associated with said at least one item; and delivery means for delivering in bulk, a plurality of sorted and grouped returns packages to a returns facility of said associated retailer.
 30. The system according to claim 29, further comprising means for submitting said returns package for pickup at a destination centralized pickup location.
 31. The system according to claim 24, further comprising means for randomly loading said bulk delivered package into said system of storage locker bins, wherein said random loading means comprises: electronics for electronically capturing an identifier for said bulk delivered package; and means for associating said electronically captured identifier of said bulk delivered package with an electronically captured identifier of one of said storage locker bins within said automated system of storage locker bins.
 32. The system according to claim 31, further comprising, retrieval means for retrieving maid bulk delivered package created for said specific recipient from a storage locker bin, said retrieval means having a computing means for authenticating an identity of said recipient prior to at least one of revealing an identity of said storage locker bin and providing access to said storage locker bin.
 33. The system according to claim 24, wherein said means for randomly loading said bulk delivered package into said system of storage locker bins comprises electronic circuitry and software for automatically triggering the dispatch of an electronic notification to said recipient of said bulk delivered package, said electronic notification having at least an identifier of said destination centralized pickup location.
 34. The system according to claim 33, wherein said electronic circuitry and software for automatically triggering the dispatch of said electronic notification further comprises circuitry and associated software for recording information necessary for billing at least one of a customer who ordered an item of said bulk delivered package, said recipient and a retailer, said information including at least one of an order identifier, an ordering customer identifier, a recipient identifier, a customer identifier, a package identifier, a delivery date, a delivery time, a delivery notification date, a delivery notification time, a retrieval date and a retrieval time.
 35. The system according to claim 33, wherein said electronic notification to said recipient comprises at least one of a facsimile, an email, a telephone call, and a page.
 36. The system according to claim 24, further comprising retrieval means for retrieval of said bulk delivered package by said recipient through self-service.
 37. The system according to claim 24, wherein said means for loading said bulk delivered package randomly into said system of storage locker bins further comprises means for loading said bulk delivered package into any unoccupied storage locker bin within said system of storage locker bins, said unoccupied storage locker bins having dimensions large enough to accept said bulk delivered package, said system of storage locker bins being configurable.
 38. The system according to claim 24, wherein said delivery means for delivering said package in bulk to said destination centralized pickup location further comprises means for accommodating delivery of said package in bulk to said destination centralized pickup location from a plurality of different shippers.
 39. The system according to claim 24, wherein said means for loading said bulk delivered package randomly into said automated system of storage locker bins further comprises means for accommodating loading of said bulk delivered package into said automated system of storage locker bins from a plurality of different shippers.
 40. The system according to claim 24, further comprising: means for creating bulk delivered customer distribution center (CDC) outbound package consisting of a least one item destined for a recipient at one of a specified destination centralized pickup location and a specified address; means for submitting said bulk delivered CDC outbound package for pickup at a destination centralized pickup location; and delivery means for delivering said CDC outbound package in bulk to one of said specified destination centralized pickup location and a destination local distribution hub.
 41. The system according to claim 24, further comprising means for grouping a plurality of packages plurality of recipients for delivery to said destination centralized pickup location, as further comprised within the package creation means at said distribution center: sorting means for sorting items organized by item identifier to a packing station associated with said destination centralized pickup location; identifying means at said packing station for identifying items for a specific recipient from said sorted items organized by item identifier; and picking means for picking said identified items for a specific recipient from said items organized by item identifier at said packing station to create a package for said specific recipient.
 42. The system according to claim 24, further comprising means for sorting at an origination distribution center, items received from at least one retailer delivered to said origination distribution center, said items destined for a plurality of said recipients, and said items organized by item identifier, wherein said package creation occurs at said origination distribution center, said origination distribution center also serving as a destination distribution center.
 43. The system according to claim 42, further comprising consolidation means for consolidating more than one of said items destined for a specific recipient, said more than one item originating from at least one retailer.
 44. The system according to claim 43, further comprising means for receiving said items associated with at least one order from at least one fulfillment location.
 45. A system for efficient bulk package delivery for recipients, the system comprising: delivery means for delivering said packages in bulk for a plurality of recipients in a single delivery stop to a destination centralized pickup location and for delivery of at least one item destined for a recipient; a means for randomly loading said bulk delivered packages into an automated system of storage locker bins; means for creating a returns package comprising at least one item from at least one of a bulk delivered package retrieved by a recipient and a package delivered to a customer specified address, said returns package destined for a retailer associated with said at least one item identification means for identifying a returns facility identifier and a returns local market identifier for said returns package based upon an identifier of said retailer, identification means for identifying a distribution center identifier associated with said returns local market identifier; means for submitting said returns package for pickup at a destination centralized pickup location; transportation means for transporting said submitted returns package from said destination centralized pickup location of said returns package submission to a destination distribution center associated with said destination centralized pickup location of said returns package submission; means for sorting and grouping at said associated destination distribution center said transported returns package by said identified distribution center identifier associated with said returns local marker identifier for bulk delivery to an origination distribution center associated with said identified distribution center identifier; transportation means for transporting said sorted and grouped returns package from said associated destination distribution center to said associated origination distribution center; means for sorting at said associated origination distribution center said transported returns package by said identified returns local market identifier of said returns package; means for sorting and grouping at said associated origination distribution center said sorted returns package by said identified returns facility identifier of said sorted returns package for bulk delivery to a returns facility associated with said associated returns facility identifier; and delivery means for delivering in bulk said sorted and grouped returns package to said associated returns facility. 